Multi-tapered suspension component

ABSTRACT

Energy storing suspension components for use in suspension systems for wheeled vehicles and trailers are disclosed. The energy storing suspension components include an axle seat portion, an end, and a limb extending between the axle seat portion and the end. The limb includes a first taper wherein the limb decreases in width as the limb extends toward the end, a second taper wherein the limb decreases in thickness as the limb extends toward the end, wherein along the limb there is at least a portion where both the first taper and second taper are present, and a third taper that is further from the axle seat portion than the first taper and wherein the limb increases in width as the limb extends toward the end. Also disclosed are combinations of bushings and energy storing suspension components having an end configured to include an eye.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention generally relates to energy storing suspensioncomponents for use in suspension systems for wheeled vehicles andtrailers, and more particularly to energy storing suspension componentshaving multiple tapers along their length, including support members,spring members, and the like, and to combinations of such energy storingsuspension components with bushings. This disclosure presents severalexample embodiments that are representative of suspension componentsthat may be utilized for particular purposes.

2. Discussion of the Prior Art

Wheeled vehicles and trailers commonly have suspension systems thatutilize suspension components, such as support members, spring members,and the like, in suspending a vehicle or trailer frame and/or bodyassembly above and connecting to the axles to which wheels are rotatablyconnected. In this context, the frame and/or body assembly generally arereferred to as the sprung portion of the vehicle or trailer and thewheels and respective axles, whether dealing with independentsuspensions or solid axle suspensions, generally are referred to as theunsprung portions of the vehicle or trailer. For ease of reference, thesuspension systems may be said to be a part of a chassis of a wheeledvehicle or trailer, with an understanding that the chassis may include aframe assembly or may be integrally constructed with a body assembly,such as in a so-called unibody construction.

Suspension systems typically include active components designed toisolate from the sprung portion the disturbances encountered by theunsprung portions, such as occur during acceleration and deceleration,or during jounce and rebound of the axle when traversing bumps in a roadsurface and the like, and to withstand lateral and roll forces, such asare encountered when cornering. Such suspension systems also typicallyare designed with an intended relative positioning of the unsprungportions to the sprung portion at rest and during normal operation ofthe vehicle or trailer. This relative positioning of the sprung portionto the unsprung portions can be influenced by component configurationsand the way in which particular components are operatively coupledtogether, and generally results in what is commonly referred to as theride height of a vehicle or trailer, which is associated with the heightof a vehicle or trailer when the suspension system is at rest and in anormal condition ready to isolate disturbances.

Over time, a variety of different components and entire suspensionsystems have been developed to alter the capacity, ride height, ridecomfort and handling characteristics of vehicles and trailers. Thedesire to alter these features with respect to suspensions may beprompted by a variety factors. However, suspension components, such assupport members, spring members, and the like, play a dynamic rolewithin a suspension system and their spring rates, both vertically andlaterally, as well as stress levels and the ability to transfer loads toadjacent structures, present complex challenges.

For instance, a vehicle may utilize a traditional leaf spring memberthat is relatively thicker in an axle seat portion where the axle iscoupled to the spring member. The spring member then may include a taperthat decreases the thickness of the spring member at an end, to permitthe end to be formed into an upturned eye. Such a spring membertypically will have an axle seat portion that has a greater width thanthickness and will be configured to have an adequate vertical springrate to handle vertical loads and disturbances encountered on roads.Thus, this type of suspension component typically has a largestcross-sectional area in an axle seat portion, often with the axle seatportion having a greater width than thickness, and may taper to decreasein thickness and taper to increase in width at the spring member ends.In this manner, the spring member may maintain a somewhat similar orcontinuously decreasing cross-sectional area along its length.

However, such common prior art designs can lead to production of heavyspring members having an adequate vertical spring rate but asignificantly higher lateral spring rate than otherwise would benecessary. This can result in unacceptable stress concentrations in thespring member near the axle seat portion under lateral bending, and inthe transfer of excessive and potentially damaging loads to the couplingassemblies that are used to operatively couple the spring member to thechassis and to the axle. However, if a spring member and its couplingassemblies are configured with a combined bushing and lateral springrate that is too low, then the lateral loads induced during articulationof the spring member will not be adequately transferred to the couplingcomponents. In such instances, the loads are transferred to the verticaldirection, resulting in higher and potentially unacceptable verticalstresses.

The present disclosure addresses shortcomings found in prior artsuspension components for wheeled vehicles and trailers and in energystoring suspension components and bushings utilized therein.

SUMMARY OF THE INVENTION

The present disclosure generally provides energy storing suspensioncomponents and bushings for wheeled vehicles and trailers that havefeatures that can provide support members, spring members, and the like,with enhanced performance characteristics. The components may be used insuspension systems in front or rear suspensions of chassis for motoredvehicles, as well as trailers. By changing the section inertia in whatis commonly referred to as a front or first limb, or in the rear orsecond limb (also commonly referred to as a cantilever) of a supportmember, spring member, or the like, specifically by modifying the widthand thickness of the material simultaneously along at least a portionthereof, and changing the tapers along the length thereof, one is ableto maintain relatively constant stress in both vertical bending andlateral bending. This, in turn, allows for more lateral bendingdeflection before failure, and better fatigue life under largerdeflections when compared to prior art support members, spring members,and the like. The greater lateral compliance also reduces the loadspushed off to the coupling assemblies for the energy storing suspensioncomponent, reducing the stresses therein, and reducing the rollstiffness. In addition, such energy storing suspension components may beparticularly advantageously utilized when used in combination with lowaxial rate bushings, and particularly bushings having high radial toaxial rate ratios.

The changes in section inertia in a limb of an energy storing suspensioncomponent, such as a support member, spring member, or the like, may beachieved in various configurations. Preferably such changes includetapers in a first or second limb wherein the limb decreases in width andin thickness as the limb extends from an axle seat portion toward anend, and then a reversal in taper at least such that the limb thenincreases in width when continuing to extend toward the respective endof the energy storing suspension component. While tapers having avarying linear width or thickness are preferred, other taperconfigurations may be utilized. The energy storing suspension componentmay include multiple tapers in width and/or thickness, as well.Moreover, further enhancements, such as in mass reduction or stressreduction, may be gained by not just utilizing such tapers in one limb,but in some configurations by also including at least one taper in widthand/or thickness in the axle seat portion and/or in both a first and asecond limb, if the energy storing suspension component includes bothlimbs.

Unlike prior art devices having tapers, the energy storing suspensioncomponents disclosed herein include support members, spring members, andthe like, that include a first and/or second limb having tapers thatdecrease both the width and thickness within a portion of the limb asthe limb extends from an axle seat portion and toward an end, with areversal in at least the width taper so as to increase in width as thelimb further extends toward the end of the energy storing suspensioncomponent. This disclosure also includes examples of limbs that havemultiple tapers that change in magnitude, stop and reverse as the limbextends from an axle seat portion and toward an end. These potentialvariations also may be employed in a first and/or second limb of anenergy storing suspension component, such as a support member, springmember, or the like.

There are numerous additional variations in suspension components,including energy storing suspension components and bushings, includingbut not limited to low axial rate bushings, that are contemplated andconsidered to be within the scope of this disclosure, including forinstance that an axle seat portion of a suspension component mayinclude, for locating and/or mounting purposes, one or more vertical orlateral holes therethrough, a locating stud, or no hole or stud.Further, the axle seat portion of the energy storing suspensioncomponent may have a greater thickness than width, may have a greaterwidth than thickness, or may have a square cross-section, and the axleseat portion may include one or more tapers in width or in thickness, orno taper at all.

Depending on the mounting configuration and desired location of thesuspension components relative to the sprung portion of the wheeledvehicle or trailer, a first and/or second end of an energy storingsuspension component may be formed with a configuration to beoperatively coupled to a frame member. For instance, a first or secondframe member coupling assembly may engage a first or second end of anenergy storing suspension component that is bent into a couplingportion, such as an eye. Such an eye may be in the form of an upturnedeye, a Berlin eye, a downturned eye, or other shapes, and may be used incombination with various bushings, with particularly advantageousresults being achieved with low axial rate bushings. The end also may beformed as a straight end having parallel or tapered upper and lowersurfaces, such as may be configured to be operatively coupled to a framemember coupling that is configured with a wear plate that may be in theform of a slipper pad or a cam. The suspension components also may beconfigured to include components to operatively couple a damper or shockabsorber to a frame member and to an axle, or a support member, springmember, or the like.

In a first aspect, disclosed herein is an energy storing suspensioncomponent that includes an axle seat portion, an end, and a limbextending between the axle seat portion and the end. The limb includes afirst taper wherein the limb decreases in width as the limb extendstoward the end, a second taper wherein the limb decreases in thicknessas the limb extends toward the end, wherein along the limb there is atleast a portion where both the first taper and second taper are present,and a third taper that is further from the axles seat portion than thefirst taper and wherein the limb increases in width as the limb extendstoward the end.

In a second aspect, disclosed herein is an energy storing suspensioncomponent having the features set forth above with respect to the firstaspect, and wherein the end is a first end and the limb is a first limb,and further including a second end, and a second limb extending betweenthe axle seat portion and the second end. The second limb includes afirst taper wherein the second limb decreases in width as the secondlimb extends toward the second end, a second taper wherein the secondlimb decreases in thickness as the second limb extends toward the secondend, wherein along the second limb there is at least a portion whereboth the first taper and second taper are present, and a third taperthat is rearward of the first taper and wherein the second limbincreases in width as the second limb extends toward the second end.

In a third aspect, disclosed herein is an energy storing suspensioncomponent in combination with a bushing that includes an energy storingsuspension component having an axle seat portion, an end configured toinclude an eye, and a limb extending between the axle seat portion andthe end, wherein the limb comprises a first taper wherein the limbdecreases in width as the limb extends toward the end, a second taperwherein the limb decreases in thickness as the limb extends toward theend, wherein along the limb there is at least a portion where both thefirst taper and second taper are present, and a third taper that isfurther from the axle seat portion than the first taper and wherein thelimb increases in width as the limb extends toward the end, and furtherincludes a low axial rate bushing configured to be received by the eyeof the energy storing suspension component.

Thus, the present disclosure presents examples of energy storingsuspension components and combinations of such components with bushingsto be advantageously used in suspension systems for the chassis ofwheeled vehicles and trailers.

It is to be understood that both the foregoing general description andthe following detailed description are exemplary and provided forpurposes of explanation only, and are not restrictive of the subjectmatter claimed. Further features and objects of the present disclosurewill become more fully apparent in the following description of exampleembodiments and from the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

In describing the preferred examples, reference is made to theaccompanying drawing figures wherein like parts have like referencenumerals, and wherein:

FIGS. 1A-1D are front perspective, top, side and end views,respectively, of a first example of a portion of a suspension systemutilizing an energy storing suspension component and bushing that islocated along a frame member of a wheeled vehicle or trailer.

FIGS. 1E-1G are front perspective, top and side views, respectively, ofthe first example energy storing suspension component that is shown inFIGS. 1A-1D.

FIGS. 2A-2D are front perspective, top, side and end views,respectively, of a second example of a portion of a suspension systemutilizing an energy storing suspension component and bushing that islocated along a frame member of a wheeled vehicle or trailer.

FIGS. 2E-2G are front perspective, top and side views, respectively, ofthe second example energy storing suspension component that is shown inFIGS. 2A-2D.

FIGS. 3A-3D are front perspective, top, side and end views,respectively, of a third example of a portion of a suspension systemutilizing an energy storing suspension component and bushing that islocated along a frame member of a wheeled vehicle or trailer.

FIGS. 3E-3G are front perspective, top and side views, respectively, ofthe third example energy storing suspension component that is shown inFIGS. 3A-3D.

FIGS. 4A-4D are front perspective, top, side and end views,respectively, of a fourth example of a portion of a suspension systemutilizing an energy storing suspension component and bushing that islocated along a frame member of a wheeled vehicle or trailer.

FIGS. 4E-4G are front perspective, top and side views, respectively, ofa fourth example energy storing suspension component that is shown inFIGS. 4A-4D.

FIGS. 5A-5D are front perspective, top, side and end views,respectively, of a fifth example of a portion of a suspension systemutilizing an energy storing suspension component and bushing that islocated along a frame member of a wheeled vehicle or trailer.

FIGS. 5E-5G are front perspective, top and side views, respectively, ofa fifth example energy storing suspension component that is shown inFIGS. 5A-5D.

FIGS. 6A-6D are front perspective, top, side and end views,respectively, of a sixth example of a portion of a suspension systemutilizing an energy storing suspension component and bushing that islocated along a frame member of a wheeled vehicle or trailer.

FIGS. 6E-6G are front perspective, top and side views, respectively, ofa sixth example energy storing suspension component that is shown inFIGS. 6A-6D.

FIGS. 7A-7D are front perspective, side, top, and rear views,respectively, of a seventh example of portions of a suspension systemutilizing an energy storing suspension component and bushing that islocated along frame members of a wheeled vehicle or trailer.

FIG. 7E is a front perspective view of a fabricated second limb andcross-channel for the seventh example energy storing suspensioncomponents that are shown in FIGS. 7A-7D.

FIGS. 7F-7H are front perspective, top and side views, respectively, ofthe seventh example energy storing suspension component that is shown inFIGS. 7A-7E.

FIGS. 8A-8C are front perspective, top and side views, respectively, ofan eighth example energy storing suspension component for use incombination with bushings in a suspension system.

FIGS. 9A-9C are front perspective, top and side views, respectively, ofa ninth example energy storing suspension component for use in asuspension system.

FIGS. 10A-10C are front perspective, top and side views, respectively,of a tenth example energy storing suspension component for use incombination with bushings in a suspension system.

FIGS. 11A-11F are perspective, end and side views of example bushingsthat may be used with any of the example energy storing suspensioncomponents having an end configured to include an eye, in a firstconfiguration shown in FIG. 11A with an outer can or in a secondconfiguration shown in FIG. 11C without an outer can.

FIGS. 12A-12B are perspective and end views of further example bushingsthat may be used with any of the example energy storing suspensioncomponents having an end configured to include an eye, in a firstconfiguration shown in FIG. 12A with an outer can or in a secondconfiguration shown in FIG. 12B without an outer can.

FIG. 13 is a perspective view of another example bushing that may beused with any of the example energy storing suspension components havingan end configured to include an eye, and may be used with or without anouter can.

FIG. 14 is a perspective view of yet another example bushing that may beused with any of the example energy storing suspension components havingan end configured to include an eye, and may be used with or without anouter can.

It should be understood that the drawings are not to scale. While somemechanical details of energy storing suspension components and bushingsused therewith, including details of fastening means, connection to wellknown vehicle components, and other plan and section views of theparticular components, have been omitted, such details were removed forbetter viewing of the main components and are considered within thecomprehension of those skilled in the art in light of the presentdisclosure. It also should be understood that the present disclosure isnot limited to the examples illustrated.

DETAILED DESCRIPTION

This disclosure presents energy storing suspension components, such assupport members, spring members, and the like, that may be used insuspension systems on chassis, on the front or rear of wheeled vehiclesor trailers. Several example energy storing suspension components foruse in the suspension systems are disclosed herein, as well as aparticularly advantageous bushings for use in combination with one ofthe example energy storing suspension components having an endconfigured to include an eye. It will be apparent that each exampleenergy storing suspension component includes an axle seat portion, anend, and a limb extending between the axle seat portion and the end,with the limb including a first taper wherein the limb decreases inwidth as the limb extends toward the end, a second taper wherein thelimb decreases in thickness as the limb extends toward the end, whereinalong the limb there is at least a portion where both the first taperand second taper are present, and a third taper that is further from theaxle seat portion than the first taper and wherein the limb increases inwidth as the limb extends toward the end. It will be appreciated thatthe end and limb of the energy storing suspension components may bereferring to a front or first end and front or first limb, a rear orsecond end and rear or second limb, or may be referring to an energystoring suspension component having both first and second ends and firstand second limbs that include the aforementioned configuration, and thatnumerous additional configurations and uses are contemplated.

Turning to FIGS. 1A-1D, a first example suspension system 10 isillustrated for coupling a longitudinally extending frame member 12 onone side of a chassis of a wheeled vehicle or trailer to a laterallyextending axle 14 that is disposed below the frame member 12. As withthe other drawings in this disclosure, it will be appreciated that thefigures show a system for one side of a wheeled vehicle or trailer and asimilar system would be provided on the opposite side to form a fullsuspension system. The first example suspension system 10 includes anenergy storing suspension component 16, which in this first example isshown in a configuration of a support member. A general description ofthe suspension system 10 first will be provided, followed by a moredetailed description of the first example energy storing suspensioncomponent 16.

In the first example suspension system 10, the axle 14 is operativelycoupled to the energy storing suspension component 16 by an axlecoupling assembly 18 that is configured to connect the axle 14 to theenergy storing suspension component 16. In this example, the energystoring suspension component 16 is in an overslung configuration,extending over the axle 14. From the top of the axle coupling assembly18 downward, the axle coupling assembly includes a first mounting pad20, also known as a first guide plate or clamp plate, which in thisconfiguration rests on the energy storing suspension component 16, anoptional caster wedge 22 is disposed between the energy storingsuspension component 16 and the axle 14, a second mounting pad 24, alsoknown as a second guide plate or clamp plate, is located in this examplebelow the axle 14. A pair of U-shaped bolts 26 are used to clamptogether the aforementioned components between the first and secondmounting pads 20 and 24.

As will be appreciated by those skilled in the art, vehicles often havea biased, fixed caster for each axle and different axles often havedifferent desirable biased, fixed caster angles. Accordingly, if it isdesired to include a fixed caster angle of the axle 14 in a suspensionsystem, then a caster wedge 22 may be positioned between the axle seatportion of the energy storing suspension component 16 and the axle 14.It will be appreciated that, while this type of axle coupling assemblyis illustrated, the scope of this disclosure is not to be limited tosuch an assembly, as other configurations and components may be utilizedto couple an energy storing suspension component 16 to an axle 14, and acaster angle optionally may be provided and, depending on the axleassembly coupling utilized, a caster angle may be incorporated into acomponent other than a caster wedge.

As will be discussed in more detail below, the energy storing suspensioncomponent 16 is operatively coupled to the frame member 12 by a firstframe member coupling assembly 28, which in this example is at thefront, and which is in the form of a mounting bracket 30, and which inthis example includes a bushing 32 connected thereto. The bushing 32 inthis example is a shown in simplified form, but may be of variousconstructions, although examples of particularly advantageous low axialrate bushings are discussed below in more detail and in reference toFIGS. 11A-11F, 12A-12B, 13 and 14.

The example energy storing suspension component 16 shown in FIGS. 1A-1Galso is operatively coupled to the frame member 12 by a second framemember coupling assembly 34 at the rear, which in this example is in theform of an upper air spring mounting bracket, because this suspensionsystem 10 includes an air spring 36 disposed between the energy storingsuspension component 16 and the frame member 12.

To provide damping, the suspension system 10 includes a shock absorber38 that is operatively coupled at an upper end 40 to a frame membershock coupling 42, which is shown in the form of a mounting bracket, andat a lower end 44 to the second mounting pad 24, in a conventionalmanner, such as by a suitable fastener. It will be appreciated that somecomponents, for example, fasteners for fastening together variouscomponents are not shown, so as to provide a better view of the moremajor components. Nevertheless, it will be recognized that variousmethods of fastening together components may be utilized withoutdeparting from the scope of the present disclosure, including, forexample, nuts and bolts, lag screws, rivets, welding of various types,or any other suitable types of fasteners or fastening means.

Having provided a general description of the suspension system 10 shownin FIGS. 1A-1D, attention is turned to the isolated views in FIGS. 1E-1Gof the energy storing suspension component 16 of this first example. Asmay be seen in FIGS. 1E-1G, in this example, the energy storingsuspension component 16 includes an axle seat portion 50, a first end 52that in this example is at the front, and therefore, is forward of theaxle seat portion 50, and a first limb 54 that extends between the axleseat portion 50 and the first end 52, which can be considered a frontlimb and which includes a slight reverse arch. Also included in thisexample is a second end 56 that is at the rear and therefore is rearwardof the axle seat portion 50, and a second limb 58 that extends betweenthe axle seat portion 50 and the second end 56, which can be considereda second limb.

The axle seat portion 50 is not defined with exactness, but is a portionalong the energy storing suspension component 16 where the axle iscoupled thereto. Somewhat similarly, the first end 52 and second end 56are not intended to refer to a distal most surface at the ends of therespective first limb 54 and second limb 58, but rather should beconsidered those regions near to and including the distal ends of theenergy storing suspension component 16. The axle seat portion 50 of thefirst example is not shown with locating holes or embedded studs, so asto better show the main components, but it will be appreciated that suchfeatures could be included if desired for a particular configuration.

The energy storing suspension component 16 generally has an uppersurface 60 and a lower surface 62, and a thickness of the energy storingsuspension component 16 can be determined at any selected position alongits length, by measuring the distance between the upper surface 60 andlower surface 62 at the selected position. Similarly, the energy storingsuspension component 16 has a right side surface 64 and a left sidesurface 66, as viewed in this example from above and looking in aforward direction of the component. Accordingly, a width of the energystoring suspension component 16 can be determined at any selectedposition along the length of the energy storing suspension component 16,by measuring the distance between the right side surface 64 and the leftside surface 66 at the selected position.

It will be appreciated that throughout this disclosure, with respect tothe descriptions of all of the examples provided, terms such as upper,lower, top, bottom, left, right, front and rear, all are relative termsand are not intended to be limiting because they depend on the contextin which they are used and the relative position of the device at thetime.

Given the focus on changes in thickness and width within an energystoring suspension component within this disclosure, the drawingsinclude lines on the upper, lower, right side and left side surfaces,60, 62, 64, 66, respectively, that are intended to indicate where adimensional change occurs, which assists the viewer in determining wheretapers in thickness and width are occurring. Tapers and their changes inthickness and width may be appreciated by comparing the respectiveisolated views of the energy storing suspension component, such as whenviewing the first example energy storing suspension component 16 inFIGS. 1E-1G. For instance, the significance of the vertical line 70 thatis shown in FIGS. 1E and 1G on the left side surface 66 of the axle seatportion 50, is apparent in FIG. 1F, which illustrates that the axle seatportion 50 has a taper that decreases in width from forward of the axleseat portion 50, actually starting in the first limb 54 at vertical line72 and continuing into to the axle seat portion 50 until the position atthe vertical line 70, where the axle seat portion 50 then transitions toa constant width and extends rearward into the second limb 58.

As may be seen in FIGS. 1E-1G, the axle seat portion 50 of the firstexample has a greater thickness than width, and includes at least ataper that decreases in width in the forward portion of the axle seatportion 50, as the energy storing suspension component tapers todecrease in width between the positions indicated from the vertical line72 to the vertical line 70. Thus, while the axle seat portion 50 isgenerally located between the positions indicated at the lateral lines90 and 92, and has a constant thickness therebetween, there is a taperin the axle seat portion 50 that would be generally located in theforward portion of the axle seat portion 50, between the positionsindicated at the lateral line 90 and the vertical line 70, and thenthere is a portion having constant width between the positions indicatedat the vertical line 70 and the lateral line 92.

The first example energy storing suspension component 16 does notincorporate typical tapers found in prior art devices. Rather, it isapparent in FIGS. 1E-1G that the energy storing suspension component 16has a first limb 54 that in this first example includes a first taper asthe first limb 54 extends from the axle seat portion 50 toward the firstend 52 and which begins at the position of the vertical line 72, whereinthe first limb 54 decreases in width from the position at the verticalline 72 to the position at the vertical line 76 as the first limb 54extends toward the first end 52. Indeed, it becomes apparent whenviewing the related FIGS. 1E-1G, that the first limb 54 has a minimumwidth occurring along its length at a position associated with thevertical line 76. The first limb 54 includes a second taper wherein thefirst limb 54 decreases in thickness from the position at the lateralline 78 to the position at the lateral line 80 as the first limb 54extends from the axle seat portion 50 toward the first end 52, as may beappreciated when comparing FIGS. 1E and 1F to FIG. 1G. Such a comparisonalso shows that along the first limb 54 there is at least a portionwhere both the first taper and second taper are present. The first limb54 further includes a third taper that is further from the axle seatportion 50 than the first taper wherein the first limb 54 increases inwidth from the position at the vertical line 76 to the position at thevertical line 84 as the first limb 54 extends toward the first end 52.

The increased width at the first end 52 is beneficial to the structureof the first end 52. In this first example, the first end 52 isconfigured to include an upturned eye 86. This may be seen whencomparing FIGS. 1E and 1G to FIG. 1F. The energy storing suspensioncomponent 16 is operatively coupled to the frame member 12 at theupturned eye 86 via the first frame member coupling assembly 28. As maybe seen in FIGS. 1A and 1C, the first frame member coupling assembly 28includes the bushing 32 that passes through the eye 86 and is connectedto the mounting bracket 30 that is further connected to the frame member12. The tapers in the first limb 54 of the energy storing suspensioncomponent 16 provide an advantageous, more compliant lateral springrate, as well as constant vertical and lateral stress in the first limb54, while also reducing the forces transferred to the first frame membercoupling assembly 28 and to the axle coupling assembly 18. Thisreduction in lateral stiffness permits a reduction in roll stiffness.

As may be seen in FIGS. 1E-1G, the energy storing suspension component16 of the first example actually includes multiple tapers both in widthand thickness along its length. The use of the aforementionedcombination of tapers is contrary to the normal practices within theprior art, and permits advantageous reductions in mass and improvedlateral compliance, while achieving generally constant vertical andlateral stress along the first limb 54. Some of the additional taperswill be noted, such as, the first limb 54 including a further fourthtaper that is further from the axle seat portion 50 than the secondtaper wherein the first limb 54 decreases in thickness from the positionat the lateral line 80 to the position at the lateral line 88, as may beappreciated when comparing FIGS. 1E and 1F to FIG. 1G. It becomesapparent when viewing the related FIGS. 1E-1G, that the first limb 54has a minimum thickness occurring along its length at a positionassociated with the lateral line 88, which is not coincident with theminimum width of the first limb 54. Yet a further taper in the firstlimb 54 is further from the axle seat portion than the second and fourthtapers wherein the first limb 54 increases in thickness from theposition at the lateral line 88 as it extends toward the first end 52.This additional thickness is beneficial when moving into the first end52 and in the forming of the upturned eye 86.

Another of the tapers may be seen just forward of the axle seat portion50, as the first limb 54 extends from the axle seat portion 50 towardthe first end 52, where the first limb 54 includes a further taperwherein the first limb 54 decreases in thickness from the position atthe lateral line 90 to the position at the lateral line 78, as may beappreciated when comparing FIGS. 1E and 1F to FIG. 1G. This additionaltaper in thickness is beneficial for mass reduction, and provides afaster rate of reduction in thickness. This permits a relatively fasttransition from a sufficiently thick axle seat portion 50 to anappropriate thickness that can then taper more gradually within a largerportion of the first limb 54 for managing spring rates and stresses.

The energy storing suspension component 16 of the first example isconfigured as a support member that includes a second limb 58 in therear, and is in the form of a Z-beam, with a bent or kicked tail orsecond end. As such, the second end 56 is able to be located directlybelow and coupled to the air spring 36. So as to provide better viewingof the more major components of the suspension system 10, the second end56 is shown without mounting holes or a coupling that would be clampedto the second end 56 of the second limb 58 for connection to the airspring 36. The second limb 58 also includes a taper wherein the secondlimb 58 decreases in thickness from the position at the lateral line 92to the position at the lateral line 94 as it extends toward the secondend 56. This may be appreciated when comparing FIGS. 1E and 1F to FIG.1G. This further taper in thickness is beneficial in mass reduction andpermits the second limb 58 to be appropriately sized for supporting theair spring 36. It should be noted that from the vertical line 70 withinthe axle seat portion 50 extending toward the vertical line 96 in thesecond limb 58, there is a constant thickness, and the vertical line 96introduces the lateral bending within the second limb 58 while thelateral line 94 also introduces the vertical bending within the secondlimb 58.

It will be appreciated that the use of the above described multipletapers in width and thickness provides a highly advantageous energystoring suspension component 16, in the form of a support member that isusable in a suspension for a chassis of a wheeled vehicle or trailer.While linear tapers are shown in this first example, this disclosure isnot intended to be limited to linear tapers and it will be appreciatedthat other forms of tapers, such as parabolic, and the like, also couldbe utilized. Such an energy storing suspension component 16 can beconstructed of various materials, and preferably is made of metal, suchas steel. The energy storing suspension component 16 also preferablywill be produced by multiple rolling processes to affect the width andthickness of the various portions along its length, but there is nointention of limiting the method of manufacture, which could includeother processes to achieve a finished product, such as, for example,casting, forging or other suitable techniques or combinations oftechniques.

It also will be appreciated that the tapers may be present in the firstand/or second limbs, depending on the configuration of an energyabsorbing suspension component desired. Also, while the transitions fortapers in width and thickness need not necessarily occur at the sameposition along an energy storing suspension component, in this firstexample energy storing suspension component 16, as may be seen in FIG.1E, there are tapers in width and thickness in the first limb 54 thatoccur at the same position along the first limb 54, as indicated byvertical line 76 and lateral line 80. Similarly, there is a change inthe taper with respect to both width and thickness at the same positionwithin the first limb 54, as indicated by the vertical line 72 and thelateral line 78. A coincident change in taper affecting width andthickness also occurs within the second limb 58 at a position along itslength, as indicated by the vertical line 96 and the lateral line 94. Asstated, such transitions need not be coincident along the length of therespective limb. However, in an effort to produce an energy storingsuspension component 16 having constant vertical and lateral stressalong its length, it has been observed that it is beneficial when makinga taper to change in one of width or thickness, that there also be ataper to change in the other aspect.

Turning to FIGS. 2A-2D, a second example suspension system 110 isillustrated for coupling a longitudinally extending frame member 112 onone side of a chassis of a wheeled vehicle or trailer to a laterallyextending axle 114 that is disposed below the frame member 112. Thesecond example suspension system 110 includes an energy storingsuspension component 116, which in this second example is shown in aconfiguration of a Z-beam support member, but having a second limb thatis in longitudinal alignment with a first limb, as opposed to the bentor kicked rear tail or second end of the first example energy suspensioncomponent 16.

The axle 114 is operatively coupled to the energy storing suspensioncomponent 116 by an axle coupling assembly 118 that is configured toconnect the axle 114 to the energy storing suspension component 116.Similar to the first example, the second example uses an overslungconfiguration, with the axle coupling assembly 118 including a firstmounting pad 120, which rests on the energy storing suspension component116, an optional caster wedge 122 is disposed between the energy storingsuspension component 116 and the axle 114, a second mounting pad 124 islocated below the axle 114, and a pair of U-shaped bolts 126 are used toclamp together the aforementioned components between the first andsecond mounting pads 120 and 124.

The energy storing suspension component 116 is operatively coupled tothe frame member 112 by a first frame member coupling assembly 128,which is in the form of a mounting bracket 130, and which in thisexample includes a bushing 132 connected thereto. The mounting bracketmay be of various configurations, and may accommodate mounting ofnumerous types of bushings, including bushings of the particularlyadvantageous types shown in FIGS. 11A-11F, 12A-12B, 13 and 14. Thisexample also has the energy storing suspension component 116 operativelycoupled to the frame member 112 by a second framer member couplingassembly 134, which in this example is in the form of an upper airspring mounting bracket, because this suspension system 110 includes anair spring 136 disposed between the energy storing suspension component116 and the frame member 112.

To provide damping, the suspension system 110 includes a shock absorber138 that is operatively coupled at an upper end 140 to a frame membershock coupling 142, which is shown in the form of a mounting bracket,and at a lower end 144 to the second mounting pad 124, in a conventionalmanner, such as by a suitable fastener. It will be appreciated that, aswas discussed with the first example, some components, for example,fasteners for fastening together various components are not shown forbetter viewing of the more major components, but various fasteningcomponents and methods of fastening may be utilized without departingfrom the scope of the present disclosure.

As may be seen in the isolated views in FIGS. 2E-2G, the energy storingsuspension component 116 includes an axle seat portion 150, a first end152 that in this example is forward of the axle seat portion 150, and afirst limb 154 that extends between the axle seat portion 150 and thefirst end 152 and includes a slight reverse arch. Also included in thisexample is a second end 156 that is rearward of the axle seat portion150, and a second limb 158 that extends between the axle seat portion150 and the second end 156. As with the first example, the axle seatportion 150 of the second example is not defined with exactness, but isa portion along the energy storing suspension component 116 where theaxle is coupled thereto. The first end 152 and second end 156 areintended to be considered those regions that are near to and includingthe distal ends of the energy storing suspension component 116. In thesecond example, the axle seat portion 150 is shown with a lateral hole168 therethrough, which can be used with the axle coupling assembly 118for connection and/or locating purposes, but it will be appreciated thatalternative configurations may be utilized, as desired, such as havingmore than one such lateral hole therethrough, or one or more verticalholes therethrough, or no holes at all.

The energy storing suspension component 116 generally has an uppersurface 160 and a lower surface 162, and a thickness can be determinedat any selected position along the length of the energy storingsuspension component 116 by measuring the distance between the uppersurface 160 and lower surface 162 at the selected position. Similarly,the energy storing suspension component 116 has a right side surface 164and a left side surface 166, as viewed from above and looking in aforward direction of the component. Accordingly, a width can bedetermined at any selected position along the length of the energystoring suspension component 116 by measuring the distance between theright side surface 164 and the left side surface 166 at the selectedposition.

FIGS. 2A-2G include lines on the upper, lower, right side and left sidesurfaces, 160, 162, 164, 166, respectively, that are intended toindicate where a dimensional change occurs, which assists in locatingwhere tapers in thickness and width are occurring in the second exampleenergy storing suspension component 116 which may be appreciated bycomparing FIGS. 2E-2G. For instance, the significance of the verticalline 170 that is shown in FIGS. 2E and 2G on the left side surface 166of the axle seat portion 150, is apparent in FIG. 2F, which illustratesthat the axle seat portion 150 has a taper that decreases in width fromforward of the axle seat portion 150, actually starting in the firstlimb 154 at vertical line 172 and continuing into to the axle seatportion 150 until the position at the vertical line 170, where the axleseat portion 150 then transitions to a constant width and extendsrearward into the second limb 158. As may be seen in FIGS. 2E-2G, theaxle seat portion 150 of the second example has a greater thickness thanwidth, and includes at least a taper that decreases in width in theforward portion of the axle seat portion 150, as the energy storingsuspension component tapers to decrease in width between the positionsindicated from the vertical line 172 to the vertical line 170. Thus,there is a taper in the axle seat portion 150 that would be generallylocated in the forward portion of the axle seat portion 150, between thepositions indicated at the lateral line 190 and the vertical line 170,and then there is a portion having constant width between the positionsindicated at the vertical line 170 and the lateral line 192.

The second example energy storing suspension component 116 incorporatestapers that are similar to the above described first example, which arenot like typical tapers found in prior art devices. FIGS. 2E-2Gillustrate that the energy storing suspension component 116 has a firstlimb 154 that is configured to include a first taper as the first limb154 extends from the axle seat portion 150 toward the first end 152,which begins at the position of the vertical line 172, wherein the firstlimb 154 decreases in width from the position at the vertical line 172to the position at the vertical line 176 as the first limb 154 extendstoward the first end 152. A minimum width of the first limb 154 occursalong its length at a position associated with the vertical line 176.The first limb 154 includes a second taper wherein the first limb 154decreases in thickness from the position at the lateral line 178 to theposition at the lateral line 180 as the first limb 154 extends towardthe first end 152, as may be appreciated when comparing FIGS. 2E and 2Fto FIG. 2G. Such a comparison also shows that along the first limb 154there is at least a portion where both the first taper and second taperare present. The first limb 154 further includes a third taper that isfurther from the axle seat portion 150 than the first taper wherein thefirst limb 154 increases in width from the position at the vertical line176 to the position at the vertical line 184 as the first limb 154extends toward the first end 152.

The increased width at the first end 152 is beneficial to the structureof the first end 152. As with the first example, the first end 152 ofthe second example is configured to include an upturned eye 186. Thismay be seen when comparing FIGS. 2E and 2G to FIG. 2F. The energystoring suspension component 116 is operatively coupled to the framemember 112 at the upturned eye 186 via the first frame member couplingassembly 128. As may be seen in FIGS. 2A and 2C, the first frame membercoupling assembly 128 includes the bushing 132 that passes through theeye 186 and is connected to the mounting bracket 130 that is furtherconnected to the frame member 112. The tapers in the first limb 154 ofthe energy storing suspension component 116 provide an advantageous,more compliant lateral spring rate, as well as constant vertical andlateral stress in the first limb 154, while also reducing the forcestransferred to the first frame member coupling assembly 128 and to theaxle coupling assembly 118.

As may be seen in FIGS. 2E-2G, the energy storing suspension component116 of the second example actually includes multiple tapers both inwidth and thickness along its length. The use of the aforementionedcombination of tapers is contrary to the normal practices within theprior art, and permits advantageous reductions in mass and improvedlateral compliance, while achieving generally constant vertical andlateral stress along the first limb 154. Additional tapers occur in thefirst limb 154, such as a further fourth taper that is further from theaxle seat portion 150 than the second taper wherein the first limb 154decreases in thickness from the position at the lateral line 180 to theposition at the lateral line 188, as may be appreciated when comparingFIGS. 2E and 2F to FIG. 2G. It becomes apparent when viewing the relatedFIGS. 2E-2G, that the first limb 154 has a minimum thickness occurringalong its length at a position associated with the lateral line 188. Yeta further taper in the first limb 154 is further from the axle seatportion 150 than the second and fourth tapers wherein the first limb 154increases in thickness from the position at the lateral line 188 as itextends toward the first end 152. This additional thickness isbeneficial when moving into the first end 152 and in the forming of theupturned eye 186.

Another of the tapers may be seen just forward of the axle seat portion150, where the first limb 154 includes a further taper wherein the firstlimb 154 decreases in thickness from the position at the lateral line190 to the position at the lateral line 178, as may be appreciated whencomparing FIGS. 2E and 2F to FIG. 2G. This additional taper in thicknessis beneficial for mass reduction, and provides a faster rate ofreduction in thickness. This permits a relatively fast transition from asufficiently thick axle seat portion 150 to an appropriate thicknessthat can then taper more gradually within a larger portion of the firstlimb 154 for managing spring rates and stresses.

With the Z-beam configuration of the energy storing suspension component116 of the second example, the second end 156 is not located directlybelow the air spring 136. Instead, the air spring 136 sits atop and isconnected to an air spring lower support 174, which is coupled to thesecond end 156, such as by welding, or by vertical and/or lateral holestherethrough, with fasteners in the form of bolts or the like, or by anyother suitable fastening means. The air spring lower support 174 may beconnected to a similar support on the opposite side of the fullsuspension system, such as by a cross member (not shown), and the airsprings may alternatively be connected to such as cross member. Thesecond limb 158 also includes a taper wherein the second limb 158decreases in thickness from the position at the lateral line 192 to theposition at the lateral line 194 as it extends toward the second end156. This may be appreciated when comparing FIGS. 2E and 2F to FIG. 2G.This further taper in thickness is beneficial in mass reduction andpermits the second limb 158 to be appropriately sized for supporting theair spring lower support 174 and the air spring 136. It should be notedthat from the vertical line 170 within the axle seat portion 150extending rearward to the vertical line 196 in the second limb 158,there is a constant thickness, and the lateral line 194 also introducesthe vertical bending within the second limb 158.

Use of the above described multiple tapers in width and thicknessprovides a highly advantageous energy storing suspension component 116,in the form of a support member that is usable in a suspension for achassis of a wheeled vehicle or trailer. While linear tapers are shownin this second example, this disclosure is not intended to be limited tolinear tapers and other forms of tapers could be utilized. The materialsand methods of manufacture for components of this second examplesuspension system are similar to those noted for the first example. Italso will be appreciated that the transitions for tapers in width andthickness need not necessarily, but may occur at the same position alongan energy storing suspension component, and in this second exampleenergy storing suspension component 116, as seen in FIGS. 2E-2G, theminimum width and thickness in the first limb 154 do not occur at thesame position. The minimum width occurs at the position indicated by thevertical line 176 and the minimum thickness occurs at the positionindicated by the lateral line 188. There is a change in the taper withrespect to both width and thickness at the same position within thefirst limb 154, as indicated along its length at the position of thevertical line 172 and the lateral line 178. A coincident change in taperaffecting width and thickness at a position also occurs within thesecond limb 158, as indicated by the vertical line 196 and the lateralline 194. As stated, such transitions need not be coincident, but aspreviously noted, it is beneficial when making a taper to change in oneof width or thickness, that there also be a taper to change in the otheraspect.

Turning to FIGS. 3A-3D, a third example suspension system 210 isillustrated for coupling a longitudinally extending frame member 212 onone side of a chassis of a wheeled vehicle or trailer to a laterallyextending axle 214 that in this example is disposed below the framemember 212. The third example suspension system 210 includes an energystoring suspension component 216, which is shown in a configurationcommonly referred to as a hockey stick-shaped support member having abent or kicked tail or rear or second limb.

The axle 214 is operatively coupled to the energy storing suspensioncomponent 216 by an axle coupling assembly 218 that is configured toconnect the axle 214 to the energy storing suspension component 216using an underslung configuration, with the energy storing suspensioncomponent 216 extending under the axle 214. The axle coupling assembly218 includes a first mounting pad 220, which in this example rests ontop of the axle 214, an optional caster wedge 222 is disposed betweenthe axle 214 and the energy storing suspension component 216, a secondmounting pad 224 is located below the energy storing suspensioncomponent 216, and a pair of U-shaped bolts 226 are used to clamptogether the aforementioned components, between the first and secondmounting pads 220 and 224.

The energy storing suspension component 216 is operatively coupled tothe frame member 212 by a first frame member coupling assembly 228,which is in the form of a mounting bracket 230, and which in thisexample includes a bushing 232 connected thereto. The bushing 232 isshown in simplified form, but the mounting bracket may be of variousconfigurations and may accommodate a bushing of various constructions,including any of the particularly advantageous low axial rate bushingsshown in FIGS. 11A-11F, 12A-12B, 13 and 14. This example also has theenergy storing suspension component 216 operatively coupled to the framemember 212 by a second frame member coupling assembly 234, which in thisexample is in the rear and is in the form of an upper air springmounting bracket, because this suspension system 210 includes an airspring 236 disposed between the energy storing suspension component 216and the frame member 212.

To provide damping, the suspension system 210 includes a shock absorber238 that is operatively coupled at an upper end 240 to a frame membershock coupling 242, which is shown in the form of a mounting bracket,and at a lower end 244 to a bracket extension of the caster wedge 222,in a conventional manner, such as by a suitable fastener. It will beappreciated that, as was discussed with the first example, somecomponents, for example, fasteners for fastening together variouscomponents are not shown for better viewing of the more majorcomponents, but various fastening components and methods of fasteningmay be utilized without departing from the scope of the presentdisclosure.

As may be seen in the isolated views in FIGS. 3E-3G, the energy storingsuspension component 216 includes an axle seat portion 250, a first end252 that in this example is forward of the axle seat portion 250, and afirst limb 254 that extends between the axle seat portion 250 and thefirst end 252 and has a bit of camber. Also included in this example isa second end 256 that in this example is rearward of the axle seatportion 250, and a second limb 258 that extends between the axle seatportion 250 and the second end 256. As with the first example, the axleseat portion 250 of the third example is not defined with exactness, butis a portion along the energy storing suspension component 216 where theaxle is coupled thereto. The first end 252 and second end 256 areintended to be considered those regions that are near to and includingthe distal ends of the energy storing suspension component 216. In thethird example, the axle seat portion 250 is shown with a vertical hole268 therethrough, which can be used with the axle coupling assembly 218for connection and/or locating purposes, but it will be appreciated thatalternative configurations may be utilized, as desired, such as havingmore than one such vertical hole therethrough, or one or more lateralholes therethrough, or no holes at all.

The energy storing suspension component 216 generally has an uppersurface 260 and a lower surface 262, and a thickness can be determinedat any selected position along the length of the energy storingsuspension component 216 by measuring the distance between the uppersurface 260 and lower surface 262 at the selected position. Similarly,the energy storing suspension component 216 has a right side surface 264and a left side surface 266, as viewed from above and looking in aforward direction of the component. Accordingly, a width can bedetermined at any selected position along the length of the energystoring suspension component 216 by measuring the distance between theright side surface 264 and the left side surface 266 at the selectedposition.

FIGS. 3A-3G include lines on the upper, lower, right side and left sidesurfaces, 260, 262, 264, 266, respectively, that are intended toindicate where a dimensional change occurs, which assists in locatingwhere tapers in thickness and width are occurring in the third exampleenergy storing suspension component 216 which may be appreciated bycomparing FIGS. 3E-3G. The axle seat portion 250 of the third example isgenerally located between the positions indicated at the lateral lines290 and 292, has a greater thickness than width, and is of constantthickness and width, with no tapers.

The third example energy storing suspension component 216 incorporatestapers that are not like typical tapers found in prior art devices.FIGS. 3E-3G illustrate that the energy storing suspension component 216has a first limb 254 that is configured to include a first taper in thisexample that is forward of the axle seat portion 250 and which begins atthe position of the vertical line 272, wherein the first limb 254decreases in width from the position at the vertical line 272 to theposition at the vertical line 276 as the first limb 254 extends towardthe first end 252. A minimum width of the first limb 254 occurs alongits length at a position associated with the vertical line 276. Thefirst limb 254 includes a second taper wherein the first limb 254decreases in thickness from the position at the lateral line 278 to theposition at the lateral line 280 as the first limb 254 extends towardthe first end 252, as may be appreciated when comparing FIGS. 3E and 3Fto FIG. 3G. Such a comparison also shows that along the first limb thereis at least a portion where both the first taper and second taper arepresent. The first limb 254 further includes a third taper that isfurther from the axle seat portion 250 than the first taper wherein thefirst limb 254 increases in width from the position at the vertical line276 to the position at the vertical line 284 as the first limb 254extends toward the first end 252.

The increased width at the first end 252 is beneficial to its structure.As with the earlier examples, the first end 252 of the third example isconfigured to include an upturned eye 286. This may be seen whencomparing FIGS. 3E and 3G to FIG. 3F. The energy storing suspensioncomponent 216 is operatively coupled to the frame member 212 at theupturned eye 286 via the first frame member coupling assembly 228. Asmay be seen in FIGS. 3A and 3C, the first frame member coupling assembly228 includes the bushing 232 that passes through the eye 286 and isconnected to the mounting bracket 230 that is further connected to theframe member 212. The tapers in the first limb 254 of the energy storingsuspension component 216 provide an advantageous, more compliant lateralspring rate, as well as constant vertical and lateral stress in thefirst limb 254, while also reducing the forces transferred to the firstframe member coupling assembly 228 and to the axle coupling assembly218.

As may be seen in FIGS. 3E-3G, the energy storing suspension component216 of the third example actually includes multiple tapers both in widthand thickness along its length. The use of the aforementionedcombination of tapers is contrary to the normal practices within theprior art, and permits advantageous reductions in mass and improvedlateral compliance, while achieving generally constant vertical andlateral stress along the first limb 254. Additional tapers occur in thefirst limb 254, such as a further fourth taper that is further from theaxle seat portion 250 than the second taper wherein the first limb 254decreases in thickness from the position at the lateral line 280 to theposition at the lateral line 288, as may be appreciated when comparingFIGS. 3E and 3F to FIG. 3G. It becomes apparent when viewing the relatedFIGS. 3E-3G, that the first limb 254 has a minimum thickness occurringalong its length at a position associated with the lateral line 288. Yeta further taper in the first limb 254 is further from the axle seatportion 250 than the second and fourth tapers wherein the first limb 254increases in thickness from the position at the lateral line 288 as itextends toward the first end 252. This additional thickness isbeneficial when moving into the first end 252 and in the forming of theupturned eye 286.

Another of the tapers may be seen in this example just forward of theaxle seat portion 250, where the first limb 254 includes a further taperwherein the first limb 254 decreases in thickness from the position atthe lateral line 290 to the position at the lateral line 278, as may beappreciated when comparing FIGS. 3E and 3F to FIG. 3G. This additionaltaper in thickness is beneficial for mass reduction, and provides afaster rate of reduction in thickness. This permits a relatively fasttransition from a sufficiently thick axle seat portion 250 to anappropriate thickness that can then taper more gradually within a largerportion of the first limb 254 for managing spring rates and stresses. Ascan be appreciated when comparing FIGS. 3E-3G, a similar taper ispresent in the second limb 258 for like advantages, wherein the secondlimb 258 decreases in thickness from the position at the lateral line292 to the position at the lateral line 294. This is followed by afurther taper wherein the second limb 258 decreases in thickness fromthe position at the lateral line 294 to the position at the lateral line298 as the second limb 258 extends toward the second end 256. A stillfurther taper is present wherein the second limb 258 decreases inthickness from the position at the lateral line 298 to the position atthe lateral line 299 as the second limb 258 further extends toward thesecond end 256. The second limb 258 begins with a constant width comingout of the axle seat portion 250 as it extends toward the second end 256and a taper in width occurs in the second limb 258 wherein the secondlimb 258 increases in width from the position at the vertical line 294to the position at the vertical line 297 as the second limb 258 furtherextends toward the second end 256.

With the hockey stick-shaped configuration of the energy storingsuspension component 216 of the third example, the second end 256 iswider than the axle seat portion 250 and provides a broader support thatis located directly below the air spring 236. In this example, the airspring 236 sits atop and is coupled to second end 256 via a verticalhole 274 through the second end 256, such as by a fastener in the formof a bolt, a nut on a threaded post, or the like.

Use of the above described multiple tapers in width and thicknessprovides a highly advantageous energy storing suspension component 216,in the form of a support member that is usable in a suspension for achassis of a wheeled vehicle or trailer. While linear tapers are shownin this third example, this disclosure is not intended to be limited tolinear tapers and other forms of tapers could be utilized. The materialsand methods of manufacture for components of this third examplesuspension system are similar to those noted for the prior examples. Italso will be appreciated that while the transitions for tapers in widthand thickness may occur at the same position along an energy storingsuspension component, in this third example energy storing suspensioncomponent 216, as may be seen in FIGS. 3E-3G, the minimum width in thefirst limb 254 occurs at the position of the vertical line 276, whilethe minimum thickness in the first limb 254 occurs at the position ofthe lateral line 288. There is a change in the taper with respect toboth width and thickness at the same position within the first limb 254,as indicated by the vertical line 276 and the lateral line 280. Acoincident change in taper affecting width and thickness also occurswithin the second limb 258, as indicated by the vertical line 296 andthe lateral line 298. A further coincident change in taper affectingwidth and thickness also occurs within the second limb 258, as indicatedby the vertical line 297 and the lateral line 299. As stated, suchtransitions need not be coincident, but as previously noted, it isbeneficial when making a taper to change in one of width or thickness,that there also be a taper to change in the other aspect.

Turning to FIGS. 4A-4D, a fourth example suspension system 310 isillustrated for coupling a longitudinally extending frame member 312 onone side of a chassis of a wheeled vehicle or trailer to a laterallyextending axle 314 that is disposed below the frame member 312. Thefourth example suspension system 310 includes an energy storingsuspension component 316, which is shown in a configuration of a supportmember.

The axle 314 is operatively coupled to the energy storing suspensioncomponent 316 by an axle coupling assembly 318 that is configured toconnect the axle 314 to the energy storing suspension component 316using an underslung configuration, with the energy storing suspensioncomponent 316 extending under the axle 314. The axle coupling assembly318 includes a first mounting pad 320, which rests on top of the axle314, a caster wedge 322 is disposed between the axle 314 and the energystoring suspension component 316, a second mounting pad 324 is locatedbelow the energy storing suspension component 316, and a pair ofU-shaped bolts 326 are used to clamp together the aforementionedcomponents.

The energy storing suspension component 316 is operatively coupled tothe frame member 312 by a first frame member coupling assembly 328,which is in the form of a mounting bracket 330, and which in thisexample includes a bushing 332 connected thereto. As with the priorexamples, the mounting bracket may be of various configurations, and mayaccommodate mounting of numerous types of bushings, including bushingsof the particularly advantageous types shown in FIGS. 11A-11F, 12A-12B,13 and 14. This example also has the energy storing suspension component316 operatively coupled to the frame member 312 by a second frame membercoupling assembly 334, which in this example is in the form of an upperair spring mounting bracket, because this suspension system 310 includesan air spring 336 disposed between a lower air spring support 346, whichis coupled to the energy storing suspension component 316 at upper andlower extensions 347, and the frame member 312.

To provide damping, the suspension system 310 includes a shock absorber338 that is operatively coupled at an upper end 340 to a frame membershock coupling 342, which is shown in the form of a mounting bracket,and at a lower end 344 to a bracket extension of the caster wedge 322,in a conventional manner, such as by a suitable fastener. It will beappreciated that, as was discussed with the first example, somecomponents, for example, fasteners for fastening together variouscomponents are not shown for better viewing of the more majorcomponents, but various fastening components and methods of fasteningmay be utilized without departing from the scope of the presentdisclosure.

As may be seen in the isolated views in FIGS. 4E-4G, the energy storingsuspension component 316 includes an axle seat portion 350, a first end352 that is forward of the axle seat portion 350, and a first limb 354that extends between the axle seat portion 350 and the first end 352 andhas a bit of camber. In this fourth example, the lower air springsupport 346 includes upper and lower extensions 347 that receive a rearportion of the axle seat portion 350 therebetween, and which areconnected thereto such as by welding or other suitable fasteningmethods. The rear portion of the axle seat portion 350 has a constantwidth and thickness that is received between the upper and lowerextensions of the lower air spring support 346. The axle seat portion350 of the fourth example is not defined with exactness, but is aportion along the energy storing suspension component 316 where the axleis coupled thereto. The first end 352 is intended to be considered aregion that is near to and including the distal end of the energystoring suspension component 316. In the fourth example, the axle seatportion 350 is shown with a lateral hole 368 therethrough, which can beused with the axle coupling assembly 318 for connection and/or locatingpurposes, and it will be appreciated that alternative configurations maybe utilized, as desired, such as having more than one such vertical holetherethrough, or one or more lateral holes therethrough, or no holes atall.

The energy storing suspension component 316 generally has an uppersurface 360 and a lower surface 362, and a thickness can be determinedat any selected position along the length of the energy storingsuspension component 316 by measuring the distance between the uppersurface 360 and lower surface 362 at the selected position. Similarly,the energy storing suspension component 316 has a right side surface 364and a left side surface 366, as viewed from above and looking in aforward direction of the component. Accordingly, a width can bedetermined at any selected position along the length of the energystoring suspension component 316 by measuring the distance between theright side surface 364 and the left side surface 366 at the selectedposition.

FIGS. 4A-4G include lines on the upper, lower, right side and left sidesurfaces, 360, 362, 364, 366, respectively, that are intended toindicate where a dimensional change occurs, which assists in locatingwhere tapers in thickness and width are occurring in the fourth exampleenergy storing suspension component 316 which may be appreciated bycomparing FIGS. 4E-4G. The axle seat portion 350 of the fourth exampleis generally located between the positions indicated at the laterallines 390 and 392. The significance of the vertical line 370 that isshown in FIGS. 4E and 4G on the left side surface 366 of the axle seatportion 350, is apparent in FIG. 4F, which illustrates that the axleseat portion 350 has a taper that decreases in width from forward of theaxle seat portion 350, actually starting in the first limb 354 atvertical line 372 and continuing into to the axle seat portion 350 untilthe position at the vertical line 370, where the axle seat portion 350then transitions to a constant width and extends rearward to the rear ofthe axle seat portion 350.

As may be seen in FIGS. 4E-4G, the axle seat portion 350 of the fourthexample has a greater thickness than width, and includes at least ataper that decreases in width in the forward portion of the axle seatportion 350, as the energy storing suspension component tapers todecrease in width between the positions indicated from the vertical line372 to the vertical line 370. Thus, there is a taper in the axle seatportion 350 that would be generally located in the forward portion ofthe axle seat portion 350, between the positions indicated at thelateral line 390 and the vertical line 370, and then there is a portionhaving constant width between the positions indicated at the verticalline 370 and the lateral line 392.

The fourth example energy storing suspension component 316 incorporatestapers that are not like typical tapers found in prior art devices.FIGS. 4E-4G illustrate that the energy storing suspension component 316has a first limb 354 that is configured to include a first taper forwardof the axle seat portion 350 and which begins at the position of thevertical line 372, wherein the first limb 354 decreases in width fromthe position at the vertical line 372 to the position at the verticalline 376 as the first limb 354 extends toward the first end 352. Aminimum width of the first limb 354 occurs along its length at aposition associated with the vertical line 376. The first limb 354includes a second taper wherein the first limb 354 decreases inthickness from the position at the lateral line 378 to the position atthe lateral line 380 as the first limb 354 extends toward the first end352, as may be appreciated when comparing FIGS. 4E-4G. Such a comparisonalso shows that along the first limb 354 there is at least a portionwhere both the first taper and second taper are present. The first limb354 further includes a third taper that is forward of the first taperwherein the first limb 354 increases in width from the position at thevertical line 376 to the position at the vertical line 384 as the firstlimb 354 extends toward the first end 352.

The increased width at the first end 352 is beneficial to the structureof the first end 352. As with the earlier examples, the first end 352 ofthe fourth example is configured to include an upturned eye 386. Thismay be seen when comparing FIGS. 4E-4G. The energy storing suspensioncomponent 316 is operatively coupled to the frame member 312 at theupturned eye 386 via the first frame member coupling assembly 328. Asmay be seen in FIGS. 4A and 4C, the first frame member coupling assembly328 includes the bushing 332 that passes through the eye 386 and isconnected to the mounting bracket 330 that is further connected to theframe member 312. The tapers in the first limb 354 of the energy storingsuspension component 316 provide an advantageous, more compliant lateralspring rate, as well as constant vertical and lateral stress in thefirst limb 354, while also reducing the forces transferred to the firstframe member coupling assembly 328 and to the axle coupling assembly318.

As may be seen in FIGS. 4E-4G, the energy storing suspension component316 of the fourth example actually includes multiple tapers both inwidth and thickness along its length. As with the earlier examples, theuse of the aforementioned combination of tapers is contrary to thenormal practices within the prior art, and permits advantageousreductions in mass and improved lateral compliance, while achievinggenerally constant vertical and lateral stress along the first limb 354.Additional tapers occur in the first limb 354, such as a further fourthtaper that is forward of the second taper wherein the first limb 354decreases in thickness from the position at the lateral line 380 to theposition at the lateral line 388, as may be appreciated when comparingFIGS. 4E-4G. A minimum thickness occurs within the first limb 354 alongits length at a position associated with the lateral line 388. Yet afurther taper in the first limb 354 is forward of the second and fourthtapers wherein the first limb 354 increases in thickness from theposition at the lateral line 388 as it extends toward the first end 352.This additional thickness is beneficial when moving into the first end352 and in the forming of the upturned eye 386.

Another of the tapers may be seen just forward of the axle seat portion350, where the first limb 354 includes a further taper wherein the firstlimb 354 decreases in thickness from the position at the lateral line390 to the position at the lateral line 378, as may be appreciated whencomparing FIGS. 4E-4G. This additional taper in thickness is beneficialfor mass reduction, and provides a faster rate of reduction inthickness. This permits a relatively fast transition from a sufficientlythick axle seat portion 350 to an appropriate thickness that can thentaper more gradually within a larger portion of the first limb 354 formanaging spring rates and stresses.

With the longitudinal configuration of the energy storing suspensioncomponent 316 of the fourth example, the lower air spring support 346coupled to the rear of the axle seat portion 350 provides a broadersupport that is located below the air spring 336. The air spring 336sits atop and is coupled to rear air spring support 346 at a verticalhole through the lower air spring support 346, such as by a fastener inthe form of a bolt, a nut on a threaded post or the like.

Use of the above described multiple tapers in width and thicknessprovides a highly advantageous energy storing suspension component 316,in the form of a support member that is usable in a suspension for achassis of a wheeled vehicle or trailer. While linear tapers are shownin this fourth example, this disclosure is not intended to be limited tolinear tapers and other forms of tapers could be utilized. The materialsand methods of manufacture for components of this fourth examplesuspension system are similar to those noted for the prior examples. Italso will be appreciated that while the transitions for tapers in widthand thickness may occur at the same position along an energy storingsuspension component, in this fourth example energy storing suspensioncomponent 316, as seen in FIGS. 4E-4G, the minimum width in the firstlimb 354 occurs at the position of the vertical line 376, while theminimum thickness in the first limb 354 occurs at the position of thelateral line 388. There is a change in the taper with respect to bothwidth and thickness at the same position within the first limb 354, asindicated by the vertical line 376 and the lateral line 380. As stated,such transitions need not be coincident, but as previously noted, it isbeneficial when making a taper to change in one of width or thickness,that there also be a taper to change in the other aspect.

Turning to FIGS. 5A-5D, a fifth example suspension system 410 isillustrated for coupling a longitudinally extending frame member 412 onone side of a chassis of a wheeled vehicle or trailer to a laterallyextending axle 414 that is disposed below the frame member 412. Thefifth example suspension system 410 includes an energy storingsuspension component 416, which is shown in a configuration commonlyreferred to as a support member having a second limb that is inlongitudinal alignment with a first limb.

The axle 414 is operatively coupled to the energy storing suspensioncomponent 416 by an axle coupling assembly 418 that is configured toconnect the axle 414 to the energy storing suspension component 416using an underslung configuration, with the energy storing suspensioncomponent 416 extending under the axle 414. The axle coupling assembly418 includes a first mounting pad 420, which rests on top of the axle414, a caster wedge 422 is disposed between the axle 414 and the energystoring suspension component 416, a second mounting pad 424 is locatedbelow the energy storing suspension component 416, and a pair ofU-shaped bolts 426 are used to clamp together the aforementionedcomponents.

The energy storing suspension component 416 is operatively coupled tothe frame member 412 by a first frame member coupling assembly 428,which is in the form of a mounting bracket 430, and which in thisexample includes a bushing 432 connected thereto. As discussed with someof the preceding examples herein, the mounting bracket and bushing maybe of various configurations, including bushings of the particularlyadvantageous types shown in FIGS. 11A-11F, 12A-12B, 13 and 14. Thepresent example also has the energy storing suspension component 416operatively coupled to the frame member 412 by a second frame membercoupling assembly 434, which in this example is in the form of an upperair spring mounting bracket, because this suspension system 410 includesan air spring 436 disposed between the energy storing suspensioncomponent 416 and the frame member 412.

To provide damping, the suspension system 410 includes a shock absorber438 that is operatively coupled at an upper end 440 to a frame membershock coupling 442, which is shown in the form of a mounting bracket,and at a lower end 444 to a bracket extension of the caster wedge 422,in a conventional manner, such as by a suitable fastener. It will beappreciated that, as was discussed with the first example, somecomponents, such as fasteners, are not shown for better viewing of themore major components, but various fastening components and methods offastening may be utilized without departing from the scope of thepresent disclosure.

As may be seen in the isolated views in FIGS. 5E-5G, the energy storingsuspension component 416 includes an axle seat portion 450, a first end452 that is forward of the axle seat portion 450, and a first limb 454that extends between the axle seat portion 450 and the first end 452 andhas a bit of camber. Also included in this example is a second end 456that is rearward of the axle seat portion 450, and a second limb 458that extends between the axle seat portion 450 and the second end 456and is relatively flat. As with the first example, the axle seat portion450 of the fifth example is not defined with exactness, but is a portionalong the energy storing suspension component 416 where the axle iscoupled thereto. The first end 452 and second end 456 are intended to beconsidered those regions that are near to and including the distal endsof the energy storing suspension component 416. In the fifth example,the axle seat portion 450 is shown with a pair of lateral holes 468therethrough, which can be used with the axle coupling assembly 418 forconnection and/or locating purposes, but it will be appreciated thatalternative configurations may be utilized, as desired, such as havingone or more such lateral holes therethrough, or one or more verticalholes therethrough, or no holes at all.

The energy storing suspension component 416 generally has an uppersurface 460 and a lower surface 462, and a thickness can be determinedat any selected position along the length of the energy storingsuspension component 416 by measuring the distance between the uppersurface 460 and lower surface 462 at the selected position. Similarly,the energy storing suspension component 416 has a right side surface 464and a left side surface 466, as viewed from above and looking in aforward direction of the component. Accordingly, a width can bedetermined at any selected position along the length of the energystoring suspension component 416 by measuring the distance between theright side surface 464 and the left side surface 466 at the selectedposition.

FIGS. 5A-5G include lines on the upper, lower, right side and left sidesurfaces, 460, 462, 464, 466, respectively, that are intended toindicate where a dimensional change occurs, which assists in locatingwhere tapers in thickness and width are occurring in the fifth exampleenergy storing suspension component 416 which may be appreciated bycomparing FIGS. 5E-5G. The axle seat portion 450 of the fifth example isgenerally located between the positions indicated at the lateral lines478 and 492. The axle seat portion 450 has a maximum thickness that isequal to the maximum width, and a taper wherein the first limb 454decreases in thickness from the position of the lateral line 490 to theposition of the lateral line 478 as the first limb 454 extends towardthe first end 452.

The fifth example energy storing suspension component 416 incorporatestapers that are not like typical tapers found in prior art devices.FIGS. 5E-5G illustrate that the energy storing suspension component 416has a first limb 454 that is configured to include a first taper whichbegins at the position of the vertical line 472, wherein the first limb454 decreases in width from the position at the vertical line 472 to theposition at the vertical line 476 as the first limb 454 extends towardthe first end 452. A minimum width of the first limb 454 occurs alongits length at a position associated with the vertical line 476. Thefirst limb 454 includes a second taper wherein the first limb 454decreases in thickness from the position at the lateral line 478 to theposition at the lateral line 480 as the first limb 454 extends towardthe first end 452, as may be appreciated when comparing FIGS. 5E-5G.Such a comparison also shows that along the first limb 454 there is atleast a portion where both the first taper and second taper are present.The first limb 454 further includes a third taper that is forward of thefirst taper wherein the first limb 454 increases in width from theposition at the vertical line 476 to the position at the vertical line484 as the first limb 454 extends toward the first end 452.

The increased width at the first end 452 is beneficial to the structureof the first end 452. As with the earlier examples, the first end 452 ofthe third example is configured to include an upturned eye 486. This maybe seen when comparing FIGS. 5E-5G. The energy storing suspensioncomponent 416 is operatively coupled to the frame member 412 at theupturned eye 486 via the first frame member coupling assembly 428. Asmay be seen in FIGS. 5A and 5C, the first frame member coupling assembly428 includes the bushing 432 that passes through the eye 486 and isconnected to the mounting bracket 430 that is further connected to theframe member 412. The tapers in the first limb 454 of the energy storingsuspension component 416 provide an advantageous, more compliant lateralspring rate, as well as constant vertical and lateral stress in thefirst limb 454, while also reducing the forces transferred to the firstframe member coupling assembly 428 and to the axle coupling assembly418.

As may be seen in FIGS. 5E-5G, the energy storing suspension component416 of the fifth example actually includes multiple tapers both in widthand thickness along its length. The use of the aforementionedcombination of tapers is contrary to the normal practices within theprior art, and permits advantageous reductions in mass and improvedlateral compliance, while achieving generally constant vertical andlateral stress along the first limb 454. Additional tapers occur in thefirst limb 454, such as a further fourth taper that is forward of thesecond taper wherein the first limb 454 decreases in thickness from theposition at the lateral line 480 to the position at the lateral line488, as may be appreciated when comparing FIGS. 5E-5G. It becomesapparent when viewing the related FIGS. 5E-5G, that the first limb 454has a minimum thickness occurring along its length at a positionassociated with the lateral line 488. Yet a further taper in the firstlimb 454 is forward of the second and fourth tapers wherein the firstlimb 454 increases in thickness from the position at the lateral line488 as it extends toward the first end 452. This additional thickness isbeneficial when moving into the first end 452 and in the forming of theupturned eye 486.

The taper within the forward portion of the axle seat portion 450 isbeneficial for mass reduction, and provides an initial rate of reductionin thickness. This permits a relatively fast transition from asufficiently thick middle of the axle seat portion 450 to an appropriatethickness that can then taper more gradually within a larger portion ofthe first limb 454 for managing spring rates and stresses. As may beappreciated when comparing FIGS. 5E-5G, a similar taper is present inthe axle seat portion 450 for like advantages, wherein it decreases inthickness from the position at the lateral line 492 to the position atthe lateral line 494. This is followed by a constant thickness and widthin the second limb 458 as it extends to the second end 456.

With the longitudinal configuration of the energy storing suspensioncomponent 416 of the fifth example, the second end 456 is not directlybelow the air spring 436. Instead, the air spring 436 sits atop and isconnected to an air spring lower support 474, which is coupled to thesecond end 456, such as by welding or other suitable fastening means.The air spring lower support 474 may be connected to a similar supporton the opposite side of the full suspension system, or may be connectedto a cross member that is connected to the respective energy storingsuspension components.

Use of the above described multiple tapers in width and thicknessprovides a highly advantageous energy storing suspension component 416,in the form of a support member that is usable in a suspension for achassis of a wheeled vehicle or trailer. While linear tapers are shownin this fifth example, this disclosure is not intended to be limited tolinear tapers and other forms of tapers could be utilized. The materialsand methods of manufacture for components of this third examplesuspension system are similar to those noted for the prior examples.

It also will be appreciated that while the transitions for tapers inwidth and thickness may occur at the same position along an energystoring suspension component, in this fifth example energy storingsuspension component 416, as seen in FIGS. 5E-5G, the minimum width inthe first limb 454 occurs at the position of the vertical line 476,while the minimum thickness in the first limb 454 occurs at the positionof the lateral line 488. There is a change in the taper with respect toboth width and thickness at the same position within the first limb 454,as indicated by the vertical line 472 and the lateral line 478. Acoincident change in taper affecting width and thickness also occurswithin the first limb 454 at the same position, as indicated by thevertical line 476 and the lateral line 480. A still further coincidentchange in taper affecting width and thickness also occurs within thefirst limb 454 at the same position, as indicated by the vertical line484 and the lateral line 488. As stated, such transitions need not becoincident, but as previously noted, it is beneficial when making ataper to change in one of width or thickness, that there also be a taperto change in the other aspect.

Turning to FIGS. 6A-6D, a sixth example suspension system 510 isillustrated for coupling a longitudinally extending frame member 512 onone side of a chassis of a wheeled vehicle or trailer to a laterallyextending axle 514 that is disposed below the frame member 512. Thesixth example suspension system 510 includes an energy storingsuspension component 516, which in this sixth example is shown in aconfiguration of a spring member, such as a leaf spring.

The axle 514 is operatively coupled to the energy storing suspensioncomponent 516 by an axle coupling assembly 518 that is configured toconnect the axle 514 to the energy storing suspension component 516. Thesixth example uses an overslung configuration, with the axle couplingassembly 518 including a first mounting pad 520, which rests on top ofthe energy storing suspension component 516, a caster wedge 522 isdisposed between the energy storing suspension component 516 and theaxle 514, a second mounting pad 524 is located below the axle 514, and apair of U-shaped bolts 526 are used to clamp together the aforementionedcomponents.

The energy storing suspension component 516 is operatively coupled tothe frame member 512 by a first frame member coupling assembly 528,which is in the form of a mounting bracket 530, and which in thisexample includes a bushing 532 connected thereto. The mounting bracketmay be of various configurations, and may accommodate mounting ofnumerous types of bushings, including bushings of the particularlyadvantageous types shown in FIGS. 11A-11F, 12A-12B, 13 and 14. Thisexample also has the energy storing suspension component 516 operativelycoupled to the frame member 512 by a second frame member couplingassembly 534, which in this example is in the form of a rear mountingbracket 546 having a cam 548 for engagement with a second end of theenergy storing suspension component 516 that includes a slipper end 556.It will be appreciated that, while not shown, such as suspension system510 also could incorporate a damper, such as a shock absorber and/or anair spring, if desired. Also, as noted with earlier examples, somecomponents, such as fasteners, are not shown so as to permit betterviewing of the more major components, but various fastening componentsand methods of fastening may be utilized without departing from thescope of the present disclosure.

As may be seen in the isolated views in FIGS. 6E-6G, the energy storingsuspension component 516 includes an axle seat portion 550, a first end552 that is forward of the axle seat portion 550, and a first limb 554that extends between the axle seat portion 550 and the first end 552 andis relatively flat. Also included in this example is a second end 556that is rearward of the axle seat portion 550, and a second limb 558that extends between the axle seat portion 550 and the second end 556and has a slight amount of camber. As with the earlier examples, theaxle seat portion 550 of the sixth example is not defined withexactness, but is a portion along the energy storing suspensioncomponent 516 where the axle is coupled thereto. The first end 552 andsecond end 556 are intended to be considered those regions that are nearto and including the distal ends of the energy storing suspensioncomponent 516. In the sixth example, the axle seat portion 550 is shownwith a vertical hole 568 therethrough, which can be used with the axlecoupling assembly 518 for connection and/or locating purposes, but itwill be appreciated that alternative configurations may be utilized, asdesired, such as having more than one such vertical hole therethrough,or one or more horizontal holes therethrough, or no holes at all.

The energy storing suspension component 516 generally has an uppersurface 560 and a lower surface 562, and a thickness can be determinedat any selected position along the length of the energy storingsuspension component 516 by measuring the distance between the uppersurface 560 and lower surface 562 at the selected position. Similarly,the energy storing suspension component 516 has a right side surface 564and a left side surface 566, as viewed from above and looking in aforward direction of the component. Accordingly, a width can bedetermined at any selected position along the length of the energystoring suspension component 516 by measuring the distance between theright side surface 564 and the left side surface 566 at the selectedposition.

FIGS. 6A-6G include lines on the upper, lower, right side and left sidesurfaces, 560, 562, 564, 566, respectively, that are intended toindicate where a dimensional change occurs, which assists in locatingwhere tapers in thickness and width are occurring in the sixth exampleenergy storing suspension component 516 which may be appreciated bycomparing FIGS. 6E-6G. For instance, the significance of the verticalline 570 that is shown in FIGS. 6E and 6G on the left side surface 566of the axle seat portion 550, is apparent in FIG. 6F, which illustratesthat the axle seat portion 550 has a taper that decreases in width fromforward of the axle seat portion 550, actually starting in the firstlimb 554 at vertical line 572 and continuing into to the axle seatportion 550 until the position at the vertical line 570, where the axleseat portion 550 then transitions to a short portion having a constantwidth and then at the position indicated at vertical line 574 increasesin width as it extends rearward into the second limb 558. As may be seenin FIGS. 6E-6G, the axle seat portion 550 of the sixth example has agreater thickness than width, and includes at least a portion having aconstant width and then tapers to increase in width as it extendsforward and rearward.

The sixth example energy storing suspension component 516 incorporatestapers that are similar to the above described first example, which arenot like typical tapers found in prior art devices. FIGS. 6E-6Gillustrate that the energy storing suspension component 516 has a firstlimb 554 that is configured to include a first taper forward of the axleseat portion 550 and which begins at the position of the vertical line572, wherein the first limb 554 decreases in width from the position atthe vertical line 572 to the position at the vertical line 576 as thefirst limb 554 extends toward the first end 552. A minimum width of thefirst limb 554 occurs along its length at a position associated with thevertical line 576. The first limb 554 includes a second taper whereinthe first limb 554 decreases in thickness from the position at thelateral line 578 to the position at the lateral line 580 as the firstlimb 554 extends toward the first end 552, as may be appreciated whencomparing FIGS. 6E-6G. Such a comparison also shows that along the firstlimb 554 there is at least a portion where both the first taper andsecond taper are present. The first limb 554 further includes a thirdtaper that is forward of the first taper wherein the first limb 554increases in width from the position at the vertical line 576 to theposition at the vertical line 584 as the first limb 554 extends towardthe first end 552.

The increased width at the first end 552 is beneficial to the structureof the first end 552. As with the first example, the first end 552 ofthe sixth example is configured to include an upturned eye 586. This maybe appreciated when comparing FIGS. 6E-6G. The energy storing suspensioncomponent 516 is operatively coupled to the frame member 512 at theupturned eye 586 via the first frame member coupling assembly 528. Asmay be seen in FIGS. 6A and 6C, the first frame member coupling assembly528 includes the bushing 532 that passes through the eye 586 and isconnected to the mounting bracket 530 that is further connected to theframe member 512. The tapers in the first limb 554 of the energy storingsuspension component 516 provide an advantageous, more compliant lateralspring rate, as well as constant vertical and lateral stress in thefirst limb 554, while also reducing the forces transferred to the firstframe member coupling assembly 528 and to the axle coupling assembly518.

As may be seen in FIGS. 6E-6G, the energy storing suspension component516 of the sixth example actually includes multiple tapers both in widthand thickness along its length. The use of the aforementionedcombination of tapers is contrary to the normal practices within theprior art, and permits advantageous reductions in mass and improvedlateral compliance, while achieving generally constant vertical andlateral stress along the first limb 554. Additional tapers occur in thefirst limb 554, such as a further fourth taper that is forward of thesecond taper wherein the first limb 554 decreases in thickness from theposition at the lateral line 580 to the position at the lateral line588, as may be appreciated when comparing FIGS. 6E-6G. It becomesapparent when viewing the related FIGS. 6E-6G, that the first limb 554has a minimum thickness occurring along its length at a positionassociated with the lateral line 588. Yet a further taper in the firstlimb 554 is forward of the second and fourth tapers wherein the firstlimb 554 increases in thickness from the position at the lateral line588 as it extends toward the first end 552. This additional thickness isbeneficial when moving into the first end 552 and in the forming of theupturned eye 586.

Another of the tapers may be seen just forward of the axle seat portion550, where the first limb 554 includes a further taper wherein the firstlimb 554 decreases in thickness from the position at the lateral line590 to the position at the lateral line 578, as may be appreciated whencomparing FIGS. 6E-6G. This additional taper in thickness is beneficialfor mass reduction, and provides a faster rate of reduction inthickness. This permits a relatively fast transition from a sufficientlythick axle seat portion 550 to an appropriate thickness that can thentaper more gradually within a larger portion of the first limb 554 formanaging spring rates and stresses.

With the spring member configuration of the energy storing suspensioncomponent 516 of the sixth example, the tapers in the second limb 558are quite similar to the tapers in the first limb 554. FIGS. 6E-6Gillustrate that the energy storing suspension component 516 has a secondlimb 558 that is configured to include a first taper rearward of theaxle seat portion 550 and which begins at the position of the verticalline 582, wherein the second limb 558 decreases in width from theposition at the vertical line 582 to the position at the vertical line596 as the second limb 558 extends toward the second end 556. A minimumwidth of the second limb 554 occurs along its length at a positionassociated with the vertical line 596.

The second limb 558 includes a second taper wherein the second limb 558decreases in thickness from the position at the lateral line 593 to theposition at the lateral line 595 as the second limb 558 extends towardthe second end 556, as may be appreciated when comparing FIGS. 6E-6G.Such a comparison also shows that along the second limb 558 there is atleast a portion where both the first taper and second taper are present.The second limb 558 further includes a third taper that is rearward ofthe first taper wherein the second limb 558 increases in width from theposition at the vertical line 596 to the position at the vertical line597 as the second limb 558 extends toward the second end 556.

Additional tapers occur in the second limb 558, such as a further fourthtaper that is rearward of the second taper wherein the second limb 558decreases in thickness from the position at the lateral line 595 to theposition at the lateral line 598, as may be appreciated when comparingFIGS. 6E-6G. It becomes apparent when viewing the related FIGS. 6E-6G,that the second limb 558 has a minimum thickness occurring along itslength at a position associated with the lateral line 598. Yet a furthertaper in the second limb 558 is rearward of the second and fourth taperswherein the second limb 558 increases in thickness from the position atthe lateral line 598 to the position at the lateral line 599 as itextends toward the second end 556. This additional thickness isbeneficial when moving into the second end 556 and in the forming of theslipper end that will engage the cam 548 or an alternative structure,such as a slipper pad.

Another of the tapers may be seen just rearward of the axle seat portion550, where the second limb 558 includes a further taper wherein thesecond limb 558 decreases in thickness from the position at the lateralline 592 to the position at the lateral line 593, as may be appreciatedwhen comparing FIGS. 6E-6G. This additional taper in thickness isbeneficial for mass reduction, and provides a faster rate of reductionin thickness. This permits a relatively fast transition from asufficiently thick axle seat portion 550 to an appropriate thicknessthat can then taper more gradually within a larger portion of the secondlimb 558 for managing spring rates and stresses.

Use of the above described multiple tapers in width and thicknessprovides a highly advantageous energy storing suspension component 516,in the form of a spring member that is usable in a suspension for achassis of a wheeled vehicle or trailer. While linear tapers are shownin this sixth example, this disclosure is not intended to be limited tolinear tapers and other forms of tapers could be utilized. The materialsand methods of manufacture for components of this sixth examplesuspension system are similar to those noted for the first example.

It also will be appreciated that the transitions for tapers in width andthickness need not necessarily occur at the same position along anenergy storing suspension component, and in this sixth example energystoring suspension component 516, as seen in FIGS. 6E-6G, the minimumwidth and thickness in the first limb 554 do not occur at the sameposition. The minimum width occurs at the position indicated by thevertical line 576 and the minimum thickness occurs at the positionindicated by the lateral line 588. There is a change in the taper withrespect to both width and thickness at the same position within thefirst limb 554, as indicated by the vertical line 572 and the lateralline 578. A coincident change in taper affecting width and thicknessalso occurs within the second limb 558, as indicated by the verticalline 582 and the lateral line 593. Other coincident changes in tapercould be noted within this sixth example. However, such transitions neednot be coincident, but as previously noted, it is beneficial when makinga taper to change in one of width or thickness, that there also be ataper to change in the other aspect.

Turning to FIGS. 7A-7H, a seventh example suspension system 610 isillustrated for coupling a longitudinally extending frame members 612 ofa chassis of a wheeled vehicle or trailer to a laterally extending axle614 that is disposed below the frame members 612. Each side of theseventh example suspension system 610 includes an energy storingsuspension component 616, which in this seventh example is shown as asupport member that is connected at its rear end to a rear support 646having upper and lower extensions 647, thereby forming a longitudinallyaligned two-piece Z-beam support member. A lower air spring supportmember 674 is coupled to each rear support 646 and, if desired, alateral control link may be utilized but it has been removed to permitmore convenient viewing of the other components within the suspensionsystem 610.

An axle 614 is shown operatively coupled to the energy storingsuspension component 616 by an axle coupling assembly 618 that isconfigured to connect the axle 614 to the energy storing suspensioncomponent 616. Similar to the second example, the seventh example usesan overslung configuration, with the axle coupling assembly 618including a first mounting pad 620, which rests on the energy storingsuspension component 616 at the upper extension 647, a coupling bracket622 is disposed along the side of the energy storing suspensioncomponent 616 where it extends over the axle 614, a second mounting pad624 is located below the axle 614, and a pair of U-shaped bolts 626 areused to clamp together the aforementioned components between the firstand second mounting pads 620 and 624.

Each of the energy storing suspension components 616 is operativelycoupled to a frame member 612 by a first frame member coupling assembly628, which is in the form of a mounting bracket 630, and which in thisexample includes a bushing 632 connected thereto. As noted with theprior examples, the mounting bracket and bushing may be of variousconfigurations, including bushings of the particularly advantageoustypes shown in FIGS. 11A-11F, 12A-12B, 13 and 14. This example also hasthe energy storing suspension component 616 operatively coupled to theframe member 612 by a second frame member coupling assembly 634, whichin this example is in the form of an upper air spring mounting bracket,because this suspension system 610 includes an air spring 636 disposedbetween the lower air spring support member 674 and the frame member612.

To provide damping, the suspension system 610 includes a shock absorber638 that is operatively coupled at an upper end 640 to a frame membershock coupling 642, which is shown in the form of a mounting bracket,and at a lower end 644 to the second mounting pad 624, in a conventionalmanner, such as by a suitable fastener. It will be appreciated that, aswas discussed with prior examples, some components, for example,fasteners for fastening together various components are not shown forbetter viewing of the more major components, but various fasteningcomponents and methods of fastening may be utilized without departingfrom the scope of the present disclosure.

As may be seen in the isolated views in FIGS. 7F-7H, the energy storingsuspension component 616 includes an axle seat portion 650, a first end652 that in this example is forward of the axle seat portion 650, and afirst limb 654 that extends between the axle seat portion 650 and thefirst end 652 and includes a slight reverse arch. The axle seat portion650 of the seventh example is generally located between the positionsindicated at the lateral lines 690 and 692. As with the prior examples,the axle seat portion 650 of the seventh example is not defined withexactness, but is a portion along the energy storing suspensioncomponent 616 where the axle is coupled thereto. The first end 652 andsecond end 692 are intended to be considered those regions that are nearto and including the distal ends of the energy storing suspensioncomponent 616. In the seventh example, the axle seat portion 650 isshown with a lateral hole 668 therethrough, which can be used with theaxle coupling assembly 618, such as for connection to the couplingbracket 622, and/or for locating purposes, but it will be appreciatedthat alternative configurations may be utilized, as desired, such ashaving more than one such lateral hole therethrough, or one or morevertical holes therethrough, or no holes at all.

The energy storing suspension component 616 generally has an uppersurface 660 and a lower surface 662, and a thickness can be determinedat any selected position along the length of the energy storingsuspension component 616 by measuring the distance between the uppersurface 660 and lower surface 662 at the selected position. Similarly,the energy storing suspension component 616 has a right side surface 664and a left side surface 666, as viewed from above and looking in aforward direction of the component. Accordingly, a width can bedetermined at any selected position along the length of the energystoring suspension component 616 by measuring the distance between theright side surface 664 and the left side surface 666 at the selectedposition.

FIGS. 7F-7H include lines on the upper, lower, right side and left sidesurfaces, 660, 662, 664, 666, respectively, that are intended toindicate where a dimensional change occurs, which assists in locatingwhere tapers in thickness and width are occurring in the seventh exampleenergy storing suspension component 616. Such changes in taper may beappreciated by comparing FIGS. 7F-7H. For instance, the significance ofthe vertical line 670 that is shown in FIGS. 7F and 7H on the left sidesurface 666 of the axle seat portion 650, illustrates that the axle seatportion 650 includes a taper that increases in width forward of thevertical line 670 and extending into the first limb 654 to the verticalline 672, with the axle seat portion 650 extending rearward of thevertical line 670 in a constant width.

As may be seen in FIGS. 7F-7H, the axle seat portion 650 of the seventhexample has a greater thickness than width. Also, there is a taper inthe axle seat portion 650 that would be generally located in the forwardportion of the axle seat portion 650, between the positions indicated atthe lateral line 690 and the vertical line 670, and then there is aportion having constant width between the positions indicated at thevertical line 670 and the lateral line 692.

The seventh example energy storing suspension component 616 incorporatestapers that are similar to the above described fourth example, which arenot like typical tapers found in prior art devices. FIGS. 7F-7Hillustrate that the energy storing suspension component 616 has a firstlimb 654 that is configured to include a first taper as the first limb654 extends from the axle seat portion 650 toward the first end 652,which begins at the position of the vertical line 672, wherein the firstlimb 654 decreases in width from the position at the vertical line 672to the position at the vertical line 676 as the first limb 654 extendstoward the first end 652. A minimum width of the first limb 654 occursalong its length at a position associated with the vertical line 676.The first limb 654 includes a second taper wherein the first limb 654decreases in thickness from the position at the lateral line 678 to theposition at the lateral line 680 as the first limb 654 extends towardthe first end 652, as may be appreciated when comparing FIGS. 7F-7H.Such a comparison also shows that along the first limb 654 there is atleast a portion where both the first taper and second taper are present.The first limb 654 further includes a third taper that is further fromthe axle seat portion 650 than the first taper wherein the first limb654 increases in width from the position at the vertical line 676 to theposition at the vertical line 684 as the first limb 654 extends towardthe first end 652.

The increased width at the first end 652 is beneficial to the structureof the first end 652. As with prior examples, the first end 652 of theseventh example is configured to include an upturned eye 686, which maybe seen in FIGS. 6F and 6H. The energy storing suspension component 616is operatively coupled to the frame member 612 at the upturned eye 686via the first frame member coupling assembly 628. As may be seen inFIGS. 7A and 7B, the first frame member coupling assembly 628 includesthe bushing 632 that passes through the eye 686 and is connected to themounting bracket 630 that is further connected to the frame member 612.It will be appreciated that the mounting bracket and bushing may be ofvarious configurations, including mounting brackets that willaccommodate bushings of the particularly advantageous types shown inFIGS. 11A-11F, 12A-12B, 13 and 14. The tapers in the first limb 654 ofthe energy storing suspension component 616 provide an advantageous,more compliant lateral spring rate, as well as constant vertical andlateral stress in the first limb 654, while also reducing the forcestransferred to the first frame member coupling assembly 628 and to theaxle coupling assembly 618.

As may be seen in FIGS. 7F-7H, the energy storing suspension component616 of the seventh example actually includes multiple tapers both inwidth and thickness along its length. The use of the aforementionedcombination of tapers is contrary to the normal practices within theprior art, and permits advantageous reductions in mass and improvedlateral compliance, while achieving generally constant vertical andlateral stress along the first limb 654. Additional tapers occur in thefirst limb 654, such as a further fourth taper that is further from theaxle seat portion 650 than the second taper wherein the first limb 654decreases in thickness from the position at the lateral line 680 to theposition at the lateral line 688, as may be appreciated in FIGS. 7F-7H.It becomes apparent when viewing these related figures that the firstlimb 654 has a minimum thickness occurring along its length at aposition associated with the lateral line 688. Yet a further taper inthe first limb 654 is further from the axle seat portion 650 than thesecond and fourth tapers wherein the first limb 654 increases inthickness from the position at the lateral line 688 as it extends towardthe first end 652. This additional thickness is beneficial when movinginto the first end 652 and in the forming of the upturned eye 686.

With the two-piece Z-beam configuration on each side of the suspensionsystem 610, the rear support 646 is not located directly below the airspring 636. Instead, each air spring 636 sits atop and is connected to alower air spring support member 674, which is coupled to the rearsupports 646, such as by welding, or by vertical and/or lateral holestherethrough, with fasteners in the form of bolts or the like, or by anyother suitable fastening means. The lower air spring support member 674in this example may be seen as providing an example of the cross memberthat was mentioned as an alternative construction that could be usedwith the second example in FIGS. 2A-2E.

Use of the above described multiple tapers in width and thicknessprovides a highly advantageous energy storing suspension component 616,in the form of a support member that is usable in a suspension for achassis of a wheeled vehicle or trailer. While linear tapers are shownin this second example, this disclosure is not intended to be limited tolinear tapers and other forms of tapers could be utilized. The materialsand methods of manufacture for components of this seventh examplesuspension system may be similar to those noted for the prior examples.It also will be appreciated that the transitions for tapers in width andthickness need not necessarily, but may occur at the same position alongan energy storing suspension component, and in this seventh exampleenergy storing suspension component 616, as seen in FIGS. 7F-7H, theminimum width and thickness in the first limb 654 do not occur at thesame position. The minimum width occurs at the position indicated by thevertical line 676 and the minimum thickness occurs at the positionindicated by the lateral line 688. There is a change in the taper withrespect to both width and thickness at the same position within thefirst limb 654, as indicated along its length at the position of thevertical line 672 and the lateral line 678. A coincident change in taperaffecting width and thickness at a position also occurs within the firstlimb 654, as indicated by the vertical line 676 and the lateral line680. As stated, such transitions need not be coincident, but aspreviously noted, it is beneficial when making a taper to change in oneof width or thickness, that there also be a taper to change in the otheraspect.

An eighth example of an energy storing suspension component 716 isillustrated in FIGS. 8A-8C. The eighth example of an energy storingsuspension component 716 is illustrated as a spring member in aconfiguration of a leaf spring having a Berlin eye at each end. It willbe appreciated that this example may be used in a suspension systemsomewhat like that shown in FIGS. 6A-6D, but there may be changes toaccommodate the Berlin eye in coupling to a first frame member couplingand a different second frame member coupling would be required and mayinclude a conventional structure, such as a shackle or other bracketingand the like. Each eye may receive a bushing, such as for example, oneof the low axial rate bushing configurations shown in FIGS. 11A-11F,12A-12B, 13 and 14.

As may be appreciated from viewing FIGS. 8A-8C, the energy storingsuspension component 716 includes an axle seat portion 750, a first end752 that is forward of the axle seat portion 750, and a first limb 754that extends between the axle seat portion 750 and the first end 752 andincludes camber. Also included in this example is a second end 756 thatis rearward of the axle seat portion 750, and a second limb 758 thatextends between the axle seat portion 750 and the second end 756 andincludes camber. As with the earlier examples, the axle seat portion 750of the eighth example is not defined with exactness, but is a portionalong the energy storing suspension component 716 where the axle iscoupled thereto. The first end 752 and second end 756 are intended to beconsidered those regions that are near to and including the distal endsof the energy storing suspension component 716. In the eighth example,the axle seat portion 750 is shown with a horizontal hole 768therethrough, which can be used with the axle coupling assembly 718 forconnection and/or locating purposes, but it will be appreciated thatalternative configurations may be utilized, as desired, such as havingmore than one such horizontal hole therethrough, or one or more verticalholes therethrough, or no holes at all.

The energy storing suspension component 716 generally has an uppersurface 760 and a lower surface 762, and a thickness can be determinedat any selected position along the length of the energy storingsuspension component 716 by measuring the distance between the uppersurface 760 and lower surface 762 at the selected position. Similarly,the energy storing suspension component 716 has a right side surface 764and a left side surface 766, as viewed from above and looking in aforward direction of the component. Accordingly, a width can bedetermined at any selected position along the length of the energystoring suspension component 716 by measuring the distance between theright side surface 764 and the left side surface 766 at the selectedposition.

FIGS. 8A-8C include lines on the upper, lower, right side and left sidesurfaces, 760, 762, 764, 766, respectively, that are intended toindicate where a dimensional change occurs, which assists in locatingwhere tapers in thickness and width are occurring in the eighth exampleenergy storing suspension component 716 which may be appreciated bycomparing FIGS. 8A-8C. For instance, the significance of the verticalline 770 that is shown in FIGS. 8A and 8C on the left side surface 766of the axle seat portion 750, is apparent in FIG. 8B, which illustratesthat the axle seat portion 750 has a taper that decreases in width fromforward of the axle seat portion 750, actually starting in the firstlimb 754 at vertical line 772 and continuing into to the axle seatportion 750 until the position at the vertical line 770, where the axleseat portion 750 then transitions to a short portion having a constantwidth and then at the position indicated at vertical line 774 increasesin width as it extends rearward into the second limb 758. As may be seenin FIGS. 8A-8C, the axle seat portion 750 of the eighth example has agreater thickness than width, and includes at least a portion having aconstant width and then tapers to increase in width as it extendsforward and rearward.

The eighth example energy storing suspension component 716 incorporatestapers that are similar to the above described sixth example, which arenot like typical tapers found in prior art devices. FIGS. 8A-8Cillustrate that the energy storing suspension component 716 has a firstlimb 754 that is configured to include a first taper forward of the axleseat portion 750 and which begins at the position of the vertical line772, wherein the first limb 754 decreases in width from the position atthe vertical line 772 to the position at the vertical line 776 as thefirst limb 754 extends toward the first end 752. A minimum width of thefirst limb 754 occurs along its length at a position associated with thevertical line 776. The first limb 754 includes a second taper whereinthe first limb 754 decreases in thickness from the position at thelateral line 778 to the position at the lateral line 780 as the firstlimb 754 extends toward the first end 752, as may be appreciated whencomparing FIGS. 8A-8C. Such a comparison also shows that along the firstlimb 754 there is at least a portion where both the first taper andsecond taper are present. The first limb 754 further includes a thirdtaper that is forward of the first taper wherein the first limb 754increases in width from the position at the vertical line 776 to theposition at the vertical line 784 as the first limb 754 extends towardthe first end 752.

The increased width at the first end 752 is beneficial to the structureof the first end 752. As with the first example, the first end 752 ofthe eighth example is configured to include an upturned eye 786. Thismay be appreciated when comparing FIGS. 8A-8C. The energy storingsuspension component 716 may be operatively coupled to a frame member orunibody structure of a wheeled vehicle or trailer at the upturned eye786 via a suitable first coupling assembly, such as were described inthe earlier examples. The tapers in the first limb 754 of the energystoring suspension component 716 provide an advantageous, more compliantlateral spring rate, as well as constant vertical and lateral stress inthe first limb 754, while also reducing the forces transferred to afirst frame member coupling assembly and to an axle coupling assembly.

As may be seen in FIGS. 8A-8C, the energy storing suspension component716 of the eighth example actually includes multiple tapers both inwidth and thickness along its length. The use of the aforementionedcombination of tapers is contrary to the normal practices within theprior art, and permits advantageous reductions in mass and improvedlateral compliance, while achieving generally constant vertical andlateral stress along the first limb 754. Additional tapers occur in thefirst limb 754, such as a further fourth taper that is forward of thesecond taper wherein the first limb 754 decreases in thickness from theposition at the lateral line 780 to the position at the lateral line788, as may be appreciated when comparing FIGS. 8A-8C. It becomesapparent when viewing the related FIGS. 8A-8C, that the first limb 754has a minimum thickness occurring along its length at a positionassociated with the lateral line 788. Yet a further taper in the firstlimb 754 is forward of the second and fourth tapers wherein the firstlimb 754 increases in thickness from the position at the lateral line788 as it extends toward the first end 752. This additional thickness isbeneficial when moving into the first end 752 and in the forming of theupturned eye 786.

Another of the tapers may be seen just forward of the axle seat portion750, where the first limb 754 includes a further taper wherein the firstlimb 754 decreases in thickness from the position at the lateral line790 to the position at the lateral line 788, as may be appreciated whencomparing FIGS. 8A-8C. This additional taper in thickness is beneficialfor mass reduction, and provides a faster rate of reduction inthickness. This permits a relatively fast transition from a sufficientlythick axle seat portion 750 to an appropriate thickness that can thentaper more gradually within a larger portion of the first limb 754 formanaging spring rates and stresses.

With the spring member configuration of the energy storing suspensioncomponent 716 of the eighth example, the tapers in the second limb 758are quite similar to the tapers in the first limb 754. FIGS. 8A-8Cillustrate that the energy storing suspension component 716 has a secondlimb 758 that is configured to include a first taper rearward of theaxle seat portion 750 and which begins at the position of the verticalline 782, wherein the second limb 758 decreases in width from theposition at the vertical line 782 to the position at the vertical line796 as the second limb 758 extends toward the second end 756. A minimumwidth of the second limb 754 occurs along its length at a positionassociated with the vertical line 796. The second limb 758 includes asecond taper wherein the second limb 758 decreases in thickness from theposition at the lateral line 793 to the position at the lateral line 795as the second limb 758 extends toward the second end 756, as may beappreciated when comparing FIGS. 8A-8C. Such a comparison also showsthat along the second limb 758 there is at least a portion where boththe first taper and second taper are present. The second limb 758further includes a third taper that is rearward of the first taperwherein the second limb 758 increases in width from the position at thevertical line 796 to the position at the vertical line 797 as the secondlimb 758 extends toward the second end 756, which is formed in a similarmanner to the first end 752 so as to include a Berlin eye 787.

Additional tapers occur in the second limb 758, such as a further fourthtaper that is rearward of the second taper wherein the second limb 758decreases in thickness from the position at the lateral line 795 to theposition at the lateral line 798, as may be appreciated when comparingFIGS. 8A-8C. It becomes apparent when viewing the related FIGS. 8A-8C,that the second limb 758 has a minimum thickness occurring along itslength at a position associated with the lateral line 798. Yet a furthertaper in the second limb 758 is rearward of the second and fourth taperswherein the second limb 758 increases in thickness from the position atthe lateral line 798 to the position at the lateral line 799 as itextends toward the second end 756. This additional thickness isbeneficial when moving into the second end 756 and in the forming of theBerlin eye 787.

Another of the tapers may be seen just rearward of the axle seat portion750, where the second limb 758 includes a further taper wherein thesecond limb 758 decreases in thickness from the position at the lateralline 792 to the position at the lateral line 793, as may be appreciatedwhen comparing FIGS. 8A-8C. This additional taper in thickness isbeneficial for mass reduction, and provides a faster rate of reductionin thickness. This permits a relatively fast transition from asufficiently thick axle seat portion 750 to an appropriate thicknessthat can then taper more gradually within a larger portion of the secondlimb 758 for managing spring rates and stresses.

Use of the above described multiple tapers in width and thicknessprovides a highly advantageous energy storing suspension component 716,in the form of a spring member that is usable in a suspension for achassis of a wheeled vehicle or trailer. While linear tapers are shownin this seventh example, this disclosure is not intended to be limitedto linear tapers and other forms of tapers could be utilized. Thematerials and methods of manufacture for components of this eighthexample suspension system are similar to those noted for the firstexample. It also will be appreciated that the transitions for tapers inwidth and thickness need not necessarily occur at the same positionalong an energy storing suspension component, and in this eighth exampleenergy storing suspension component 716, as seen in FIGS. 8A-8C, theminimum width and thickness in the first limb 754 do not occur at thesame position. The minimum width occurs at the position indicated by thevertical line 776 and the minimum thickness occurs at the positionindicated by the lateral line 788. There is a change in the taper withrespect to both width and thickness at the same position within thefirst limb 754, as indicated by the vertical line 772 and the lateralline 778. A coincident change in taper affecting width and thicknessalso occurs within the second limb 758, as indicated by the verticalline 782 and the lateral line 793. Other coincident changes in tapercould be noted within this eighth example. However, such transitionsneed not be coincident, but as previously noted, it is beneficial whenmaking a taper to change in one of width or thickness, that there alsobe a taper to change in the other aspect.

A ninth example of an energy storing suspension component 816 isillustrated in FIGS. 9A-9C. The ninth example of an energy storingsuspension component 816 is illustrated as a spring member in aconfiguration of a leaf spring having a similar taper profile to that ofthe eighth example in FIGS. 8A-8C, but having a first slipper end 852 inthe front and a second slipper end 856 in the rear. The slipper ends maybe configured to be operatively coupled to a frame member by such as byuse of frame member coupling assemblies, which may be similar to thecoupling assembly 534 described above and shown in FIGS. 6A-6C, where aslipper end engages a cam of a mounting bracket, but there may bechanges to accommodate the slipper ends, as needed. In the ninthexample, there are two horizontal holes 868 through an axle seatportion, which can be used with an axle coupling assembly for connectionand/or locating purposes, but it will be appreciated that alternativeconfigurations may be utilized, as desired, such as having one suchhorizontal hole therethrough, or one or more vertical holestherethrough, or no holes at all.

As may be appreciated from viewing FIGS. 9A-9C, aside from the ends 852and 856 in place of the ends 752 and 756, and the two apertures 868 inplace of the one aperture 768 through the axle seat portion, the energystoring suspension component 816 includes the aforementionedconfiguration of the eighth example energy storing suspension component716 in FIGS. 8A-8C, and accordingly is shown with the same referencenumerals, and is subject to the same description.

A tenth example energy storing suspension component 916 may be seen inthe FIGS. 10A-10C and includes an axle seat portion 950, a first end 952that in this example is forward of the axle seat portion 950, and afirst limb 954 that extends between the axle seat portion 950 and thefirst end 952 and has a bit of camber. Also included in this example isa second end 956 that in this example is rearward of the axle seatportion 950, and a second limb 958 that also has a bit of camber andextends between the axle seat portion 950 and the second end 956. Aswith the earlier examples, the axle seat portion 950 of the tenthexample is not defined with exactness, but is a portion along the energystoring suspension component 916 where an axle may be coupled thereto.The first end 952 and second end 956 are intended to be considered thoseregions that are near to and including the distal ends of the energystoring suspension component 916. In the tenth example, the axle seatportion 950 is shown with a vertical hole 968 therethrough, which can beused with the axle coupling assembly, such as described with priorexamples, for connection and/or locating purposes, but it will beappreciated that alternative configurations may be utilized, as desired,such as having more than one such vertical hole therethrough, or one ormore lateral holes therethrough, or no holes at all.

The energy storing suspension component 916 generally has an uppersurface 960 and a lower surface 962, and a thickness can be determinedat any selected position along the length of the energy storingsuspension component 916 by measuring the distance between the uppersurface 960 and lower surface 962 at the selected position. Similarly,the energy storing suspension component 916 has a right side surface 964and a left side surface 966, as viewed from above and looking in aforward direction of the component. Accordingly, a width can bedetermined at any selected position along the length of the energystoring suspension component 916 by measuring the distance between theright side surface 964 and the left side surface 966 at the selectedposition.

FIGS. 10A-10C include lines on the upper, lower, right side and leftside surfaces, 960, 962, 964, 966, respectively, that are intended toindicate where a dimensional change occurs, which assists in locatingwhere tapers in thickness and width are occurring in the tenth exampleenergy storing suspension component 916 which may be appreciated bycomparing FIGS. 10A-10C. The axle seat portion 950 of the tenth exampleis generally located between the positions indicated at the laterallines 990 and 992, has a greater thickness than width, and is ofconstant thickness and width, with no tapers.

The tenth example energy storing suspension component 916 incorporatestapers that are not like typical tapers found in prior art devices.FIGS. 10A-10C illustrate that the energy storing suspension component916 has a first limb 954 that is configured to include a first taper inthis example that is forward of the axle seat portion 950 and whichbegins at the position of the vertical line 972, wherein the first limb954 decreases in width from the position at the vertical line 972 to theposition at the vertical line 976 as the first limb 954 extends towardthe first end 952. A minimum width of the first limb 954 occurs alongits length at a position associated with the vertical line 976.

The first limb 954 includes a second taper wherein the first limb 954decreases in thickness from the position at the lateral line 978 to theposition at the lateral line 980 as the first limb 954 extends towardthe first end 952, as may be appreciated when comparing FIGS. 10A-10C.Such a comparison also shows that along the first limb 954 there is atleast a portion where both the first taper and second taper are present.The first limb 954 further includes a third taper that is further fromthe axle seat portion 950 than the first taper wherein the first limb954 increases in width from the position at the vertical line 976 to theposition at the vertical line 984 as the first limb 954 extends towardthe first end 952.

The increased width at the first end 952 is beneficial to its structure.Similar to some of the prior examples, the first end 952 of the tenthexample is configured to include an upturned eye 986. The energy storingsuspension component 916 may be operatively coupled to a frame member atthe upturned eye 986 via a frame member coupling assembly, such as thoseused in the prior examples. As may be seen in FIGS. 10A and 10C, theupturned eye 986 may be configured to receive a bushing that would passtherethrough. The tapers in the first limb 954 of the energy storingsuspension component 916 provide an advantageous, more compliant lateralspring rate, as well as constant vertical and lateral stress in thefirst limb 954, while also reducing the forces transferred to a framemember coupling assembly and to an axle coupling assembly.

As may be seen in FIGS. 10A-10C, the energy storing suspension component916 of the tenth example actually includes multiple tapers both in widthand thickness along its length. The use of the aforementionedcombination of tapers is contrary to the normal practices within theprior art, and permits advantageous reductions in mass and improvedlateral compliance, while achieving generally constant vertical andlateral stress along the first limb 954. Additional tapers occur in thefirst limb 954, such as a further fourth taper that is further from theaxle seat portion 950 than the second taper wherein the first limb 954decreases in thickness from the position at the lateral line 980 to theposition at the lateral line 988, as may be appreciated when comparingFIGS. 10A and 10C. It is apparent that the first limb 954 has a minimumthickness occurring along its length at a position associated with thelateral line 988. Yet a further taper in the first limb 954 is furtherfrom the axle seat portion 950 than the second and fourth tapers whereinthe first limb 954 increases in thickness from the position at thelateral line 988 as it extends toward the first end 952. This additionalthickness is beneficial when moving into the first end 952 and in theforming of the upturned eye 986. The eye may receive a bushing, such asfor example, one of the bushing configurations shown in FIGS. 11A-11F,12A-12B, 13 and 14.

Another of the tapers may be seen in this example just forward of theaxle seat portion 950, where the first limb 954 includes a further taperas it decreases in thickness from the position at the lateral line 990to the position at the lateral line 978, as may be appreciated whenviewing FIG. 10A. This additional taper in thickness is beneficial formass reduction, and provides a faster rate of reduction in thickness.This permits a relatively fast transition from a sufficiently thick axleseat portion 950 to an appropriate thickness that can then taper moregradually within a larger portion of the first limb 954 for managingspring rates and stresses.

As may be appreciated when comparing FIGS. 10A-10C, the second limb 958has a constant width, but a taper is present in the second limb 958 asit decreases in thickness from the position at the lateral line 992 tothe position at a lateral line 994. This is followed by an upturned eye987 at the second end 956. As with the upturned eye 986 at the first end952, the upturned eye 987 may be configured to receive a bushing thatwould pass therethrough to operatively couple the energy storingsuspension component 916 to a frame member via a frame member couplingassembly, such as those used in the prior examples, with theunderstanding that one could utilize the particularly advantageous typesshown in FIGS. 11A-11F, 12A-12B, 13 and 14.

Use of the above described multiple tapers in width and thicknessprovides a highly advantageous energy storing suspension component 916,in the form of a leaf spring that is usable in a suspension for achassis of a wheeled vehicle or trailer. While linear tapers are shownin this tenth example, this disclosure is not intended to be limited tolinear tapers and other forms of tapers could be utilized. The materialsand methods of manufacture for components of this tenth example energystoring suspension component 916 are similar to those noted for theprior examples. It also will be appreciated that while the transitionsfor tapers in width and thickness may occur at the same position alongan energy storing suspension component, in this tenth example energystoring suspension component 916, as may be seen in FIGS. 10A-10C, theminimum width in the first limb 954 occurs at the position of thevertical line 976, while the minimum thickness in the first limb 954occurs at the position of the lateral line 988. There is a change in thetaper with respect to both width and thickness at the same positionwithin the first limb 954, as indicated by the vertical line 976 and thelateral line 980. As stated, such transitions need not be coincident,but as previously noted, it is beneficial when making a taper to changein one of width or thickness, that there also be a taper to change inthe other aspect.

Turning to FIGS. 11A-11F, 12A-12B, 13 and 14, several examples ofadvantageous bushings are illustrated. Each of the respective bushings1000A, 1000B, 1000C and 1000D may be used with or without an outer canand in combination with an energy storing suspension component via beingreceived by the eye of the energy storing suspension component, such asin any of the above first through eighth, or tenth example energystoring suspension components. These example bushings provide a lowaxial rate, such as 15,000 lbs/inch or less, and may provide aparticularly advantageous high radial to axial rate ratio.

Each of the example bushings includes a different central body 1002A,1002B, 1002C, 1002D at the center of the bushing that permits mountingto a bracket. Each bushing also may be used with or without an outer canmember 1004, which is shown as being of a similar configurationthroughout the examples. The central body and can components generallymay be constructed of various metals that would be suitable for use in asuspension system.

It will be appreciated that the central body of the example bushingsdiffer in configuration depending on how they will be coupled to thesuspension system, such as via a mounting bracket. More particularly, inthe example shown in FIGS. 11A-11F, the central body 1002A is shown as abar pin having a cylindrical center portion with extensions havingflattened surfaces that include a passage 1006A therethrough for receiptof a fastener, such as a bolt, for connection to a mounting bracket,such as is shown in the preceding example suspension systems. In theexamples shown in FIGS. 12A-12B, the central body 1002B is shown as abar pin having a cylindrical center portion with cylindrical extensionsthat may be coupled to a mounting bracket of a suspension system viaclamps that receive the cylindrical extensions. In the example shown inFIG. 13, the central body 1002C is shown as a bar pin having acylindrical center portion with D-shaped extensions having a flattenedsurface that include a passage 1006C therethrough for receipt of afastener, such as a bolt, for connection to a mounting bracket, such asis shown in the preceding example suspension systems. In the exampleshown in FIG. 14, the central body 1002D is shown as a through-boltsleeve having a cylindrical configuration with a passage 1006Dtherethrough for receipt of a fastener, such as a bolt, that may becoupled to a mounting bracket of a suspension system.

While other low axial rate bushing structures may be utilized, theexample bushings shown happen to be of the rate ring type. Rate ringbushings include a component referred to as a rate ring portion that maybe made of metal, or the like, and that is disposed between at least twoelastomeric members, to add stiffness to the bushing. In each of therespective example bushings of FIGS. 11A, 11C, 12A and 14, at least afirst elastomeric member 1008A, 1008B, 1008D, which generally may beconstructed of various types of rubber or other suitable elastomericmaterials, is bonded to the respective central body 1002A, 1002B, 1002D,and is disposed between the respective central body and an outer surfaceof the bushing. However, the at least first elastomeric member does nothave to be bonded to the central body, and indeed it is not in FIG. 13where the first elastomeric member 1008C is not bonded to the centralbody 1002C.

Given that the low axial rate bushing examples shown are of the ratering type, each bushing also includes at least one rate ring portion. Inthe examples shown in FIG. 11A, with an outer can 1004, and FIG. 11C,without an outer can, the at least one rate ring portion 1010A includestwo pieces that are configured substantially as halves of a cylinder. Inthe examples shown in FIG. 12A, with an outer can 1004, and FIG. 12B,without an outer can, the at least one rate ring portion 1010B includesa cylindrical sleeve having a passage therethrough. The example bushingsshown in FIGS. 13 and 14 each include at least one rate ring portion1010C and 1010D, respectively, that are similar to the at least one ratering portion 1010A in that they include two pieces that are configuredsubstantially as halves of a cylinder, and it will be appreciated thateach of these examples also could be utilized without an outer can. Therate ring portions disclosed generally may be constructed of variousmetals that would be suitable for use in a suspension system. The firstelastomeric member in each example is bonded to the respective rate ringportion, although the components may be otherwise connected.

The example bushings shown also each include at least a secondelastomeric member 1012A, 1012B, 1012C and 1012D, typically of a similarmaterial to that used in the aforementioned at least first elastomericmember, although the at least second elastomeric member could beconstructed of a different material, and the at least second elastomericmember is disposed outside of the at least one rate ring portion. The atleast second elastomeric member is shown as, but need not necessarilybe, bonded to the at least one rate ring portion. Moreover, when using arate ring portion that includes two or more pieces that are configuredsubstantially as portions of a cylinder, such as with 1010A, 1010C and1010D, the respective at least second elastomeric member 1012A, 1012Cand 1012D, which also may be two or more separate pieces, may be bondedto the respective two or more pieces of the rate ring portion.

When using a rate ring portion having two or more pieces, such as withthe rate ring portion 1010A, 1010C and 1010D, the two or more pieces maybe forced toward each other, resulting in pre-compression of the innerelastomeric member 1008A, 1008C and 1008D. This may be appreciated whencomparing the distance between the two pieces of the rate ring portion1010A and slight bulging of the at least one elastomeric member 1008A inFIG. 11C versus FIG. 11A. The pre-compressed assembly then may bepressed into the outer can member 1004, such as is shown in FIG. 11B, ormay be pressed directly into the eye of an energy storing suspensioncomponent. It will be appreciated that the at least second elastomericmember of the example shown in FIG. 12B may be compressed and thenpressed into the outer can 1004, as shown in FIG. 12A, or may be presseddirectly into the eye of an energy storing suspension component.

The relatively low axial rate of each of the example bushings shown isimportant because cross-articulation inputs to suspension components,such as those of a trailing beam suspension, generate vertical andlateral (axial) deflections that the spring, bushing, hanger, and clampgroup need to be able to resist. When the bushing is used in combinationwith an energy storing suspension component that has enhanced lateralcompliance, as disclosed herein, these deflections are handled betterthrough the added compliance, which reduces the loads generated in allconnecting components. Because these particular low axial rate bushingsessentially are constructed as two bushings in series, the conical andthe torsional rates, the directional inputs of which are shown in FIGS.11E and 11F, are low, as well. This keeps such rate ring bushings frombuilding too much load under articulation events. A sample bushing ofthe type shown in FIG. 11A has provided a particularly advantageous highradial to axial rate ratio, exhibiting, for example, a radial rate of185,000 lb/in and an axial rate of 7,200 lb/in, for a ratio of 25.7 to1.

It will be appreciated that, in accordance with the present disclosure,energy storing suspension components used in suspension systems may beprovided in various configurations, some of which may be in combinationwith particularly advantageous bushings. Any variety of suitablematerials of construction, configurations, shapes and sizes for thecomponents and methods of operatively coupling or connecting thecomponents may be utilized to meet the particular needs and requirementsof an end user. It will be apparent to those skilled in the art thatvarious modifications can be made in the design and construction of suchcomponents and systems without departing from the scope of the attachedclaims, and that the claims are not limited to the preferred embodimentsillustrated.

We claim:
 1. An energy storing suspension component comprising: an axleseat portion; an end; and a limb extending between the axle seat portionand the end; the limb comprising a first taper wherein the limbdecreases in width as the limb extends toward the end, a second taperwherein the limb decreases in thickness as the limb extends toward theend, wherein along the limb there is at least a portion where both thefirst taper and second taper are present, and a third taper that isfurther from the axle seat portion than the first taper and wherein thelimb increases in width as the limb extends toward the end.
 2. Theenergy storing suspension component of claim 1 wherein the limb includesa minimum width position.
 3. The energy storing suspension component ofclaim 1 wherein the limb includes a minimum thickness position.
 4. Theenergy storing suspension component of claim 3 wherein the limb includesa minimum width position that coincides with the minimum thicknessposition.
 5. The energy storing suspension component of claim 1 whereinthe first taper and the second taper begin at the same position alongthe limb.
 6. The energy storing suspension component of claim 1 whereinthe first taper and the second taper end at the same position along thelimb.
 7. The energy storing suspension component of claim 1 wherein theaxle seat portion has a maximum width and includes at least a taperwherein the axle seat portion increases or decreases in width.
 8. Theenergy storing suspension component of claim 1 wherein the axle seatportion includes multiple tapers wherein the axle seat portion varies inwidth.
 9. The energy storing suspension component of claim 1 wherein theaxle seat portion has a maximum thickness and includes at least a taperwherein the axle seat portion decreases in thickness.
 10. The energystoring suspension component of claim 1 wherein the axle seat portionhas a greater maximum thickness than maximum width.
 11. The energystoring suspension component of claim 1 wherein the axle seat portionhas a maximum thickness and a maximum width, wherein the maximumthickness is equal to the maximum width.
 12. The energy storingsuspension component of claim 1 wherein the axle seat portion includesat least one hole therethrough.
 13. The energy storing suspensioncomponent of claim 1 wherein the end is configured to include an eye.14. The energy storing suspension component of claim 1 wherein the endis configured to engage a first frame member coupling assembly having aslipper pad or a cam.
 15. The energy storing suspension component ofclaim 1 wherein the end is configured to have a constant thicknessand/or width.
 16. The energy storing suspension component of claim 1wherein the axle seat portion is configured to be connected to a lowerair spring support.
 17. The energy storing suspension component of claim1 wherein the limb further comprises a fourth taper further from theaxle seat portion than the second taper and wherein the limb increasesin thickness as the limb extends toward the end.
 18. The energy storingsuspension component of claim 1 wherein the limb comprises multipletapers wherein the limb decreases in thickness.
 19. The energy storingsuspension component of claim 1 wherein the limb comprises multipletapers wherein the limb decreases in width.
 20. The energy storingsuspension component of claim 1 wherein the limb comprises multipletapers wherein the limb increases in thickness.
 21. The energy storingsuspension component of claim 1 wherein the end is a first end and thelimb is a first limb, and the energy storing suspension componentfurther comprises a second end and a second limb extending between theaxle seat portion and the second end.
 22. The energy storing suspensioncomponent of claim 21 wherein the second limb includes at least a taperthat increases or decreases in width.
 23. The energy storing suspensioncomponent of claim 21 wherein the second limb further comprises at leasta taper wherein the second limb increases or decreases in thickness. 24.The energy storing suspension component of claim 21 wherein the secondlimb includes a minimum width position.
 25. The energy storingsuspension component of claim 21 wherein the second limb includes aminimum thickness position.
 26. The energy storing suspension componentof claim 25 wherein the second limb includes a minimum width positionthat coincides with the minimum thickness position.
 27. The energystoring suspension component of claim 21 wherein the second limbincludes at least a portion having a constant width.
 28. The energystoring suspension component of claim 21 wherein the second limbincludes at least a portion having a constant thickness.
 29. The energystoring suspension component of claim 21 wherein the second limbcomprises a first taper wherein the second limb decreases in width asthe second limb extends toward the second end, a second taper whereinthe second limb decreases in thickness as the second limb extends towardthe second end, wherein along the second limb there is at least aportion where both the first taper and second taper are present, and athird taper that is rearward of the first taper and wherein the secondlimb increases in width as the second limb extends toward the secondend.
 30. The energy storing suspension component of claim 21 wherein thesecond end includes at least one hole therethrough.
 31. The energystoring suspension component of claim 21 wherein the second end isconfigured to include an eye.
 32. The energy storing suspensioncomponent of claim 21 wherein the second end is configured to engage asecond frame member coupling assembly having a slipper pad or a cam. 33.The energy storing suspension component of claim 21 wherein the secondend is configured to have a constant thickness and/or a constant width.34. An energy storing suspension component in combination with a bushingcomprising: an energy storing suspension component comprising: an axleseat portion, an end configured to include an eye, and a limb extendingbetween the axle seat portion and the end, wherein the limb comprises afirst taper wherein the limb decreases in width as the limb extendstoward the end, a second taper wherein the limb decreases in thicknessas the limb extends toward the end, wherein along the limb there is atleast a portion where both the first taper and second taper are present,and a third taper that is further from the axle seat portion than thefirst taper and wherein the limb increases in width as the limb extendstoward the end; and a bushing having a low axial rate and beingconfigured to be received by the eye of the energy storing suspensioncomponent.
 35. The energy storing suspension component in combinationwith a bushing of claim 34 wherein the bushing also has a high radial toaxial rate ratio.
 36. The energy storing suspension component incombination with a bushing of claim 34 wherein the bushing furthercomprises a central body to which at least one elastomeric member isbonded.
 37. The energy storing suspension component in combination witha bushing of claim 36 wherein the central body includes a bar pin or asleeve having a passage therethrough.
 38. The energy storing suspensioncomponent in combination with a bushing of claim 36 wherein the bushingfurther comprising at least one rate ring portion.
 39. The energystoring suspension component in combination with a bushing of claim 38wherein the at least one rate ring portion further comprises acylindrical sleeve having a passage therethrough.
 40. The energy storingsuspension component in combination with a bushing of claim 38 whereinthe at least one rate ring portion includes two or more pieces that areconfigured substantially as portions of a cylinder.
 41. The energystoring suspension component in combination with a bushing of claim 38further comprising at least a second elastomeric member, with therespective at least one elastomeric member disposed between the centralbody and the at least one rate ring portion and the at least secondelastomeric member bonded to the at least one rate ring portion.